Replaced pushrod and now have problems

[jc143413]

Several weeks ago I had a right side cable failure in my top, much thanks to those that assisted me in the repair. I replaced both cables at the time and afterwards I replaced the right side pushrod as it seemed, at the time, that it had become bent during the torquing applied as the cable separated. The clamshell was warped slightly as well. I attempted to straighten the clamshell referencing the posts made by Toolpants, if I remember correctly, and was mostly successful although the left side clamshell is approx. 1/8 - 1/4 inch out of perfect alignment. I'm sure that others can relate to the caution involved in manually unwarping the clamshell. Considering the replacement costs, it's nerve wracking.

I'm not sure now that the pushrod was actually bent.

Current problem.

When the top is raised or lowered the left push rod, the same side that is slightly out of alignment, pops from its ball joint connector. I'm not sure if its because the cables are not perfectly synced or its because the clam shell is not perfectly aligned.

The push rod pops off at a very specific positioning of the V shaped mechanism, at approx. with the ball at an approx. 7oclock position, looking at it from the passenger side, going either up or down. The push rod end strikes the interior wall of the clamshell enclosure and pushes it off of the ball.

The top is fully functional other than the need to press the push rod back onto the ball attachment if I open or close the top.

Without disassembling the entire assembly can anyone tell me what may be the probable cause?

Do I need to attempt to perfectly align the clamshell or do I need to better sync the two cables?

Any help would be greatly appreciated.

Thanks,

Joe

[1schoir]

Several weeks ago I had a right side cable failure in my top, much thanks to those that assisted me in the repair. I replaced both cables at the time and afterwards I replaced the right side pushrod as it seemed, at the time, that it had become bent during the torquing applied as the cable separated. The clamshell was warped slightly as well. I attempted to straighten the clamshell referencing the posts made by Toolpants, if I remember correctly, and was mostly successful although the left side clamshell is approx. 1/8 - 1/4 inch out of perfect alignment. I'm sure that others can relate to the caution involved in manually unwarping the clamshell. Considering the replacement costs, it's nerve wracking.

I'm not sure now that the pushrod was actually bent.

Current problem.

When the top is raised or lowered the left push rod, the same side that is slightly out of alignment, pops from its ball joint connector. I'm not sure if its because the cables are not perfectly synced or its because the clam shell is not perfectly aligned.

The push rod pops off at a very specific positioning of the V shaped mechanism, at approx. with the ball at an approx. 7oclock position, looking at it from the passenger side, going either up or down. The push rod end strikes the interior wall of the clamshell enclosure and pushes it off of the ball.

The top is fully functional other than the need to press the push rod back onto the ball attachment if I open or close the top.

Without disassembling the entire assembly can anyone tell me what may be the probable cause?

Do I need to attempt to perfectly align the clamshell or do I need to better sync the two cables?

Any help would be greatly appreciated.

Thanks,

Joe

Joe:

The very first thing that I would try would be to swap the left and right side pushrods and see if you get the same result, or if the switch causes the problem to transfer to the other side.

If you are lucky, it may even solve the problem.

It also certainly wouldn't hurt to synchronize the two transmissions more precisely, using the cordless drill method. Remember to set the drill on the lowest torque setting to protect the inner cable.

Try the swap and let us know the results.

Regards, Maurice.

[jc143413]

Thanks for the suggestions Maurice, I will try the swap ASAP. Fat and lazy from leftovers and a cold drizzling rain all day. Will let you know as soon as I can raise myself from the recliner long enough to make the swap, probably this weekend. -_- you know how too much turkey, dressing, sweet potatoes , ham, and football can make it hard to get out of the chair. And tomorrow I have to watch Ala. vs. Aub. home state rivalry.

Thanks again.

Joe

[1schoir]

Thanks for the suggestions Maurice, I will try the swap ASAP. Fat and lazy from leftovers and a cold drizzling rain all day. Will let you know as soon as I can raise myself from the recliner long enough to make the swap, probably this weekend. -_- you know how too much turkey, dressing, sweet potatoes , ham, and football can make it hard to get out of the chair. And tomorrow I have to watch Ala. vs. Aub. home state rivalry.

Thanks again.

Joe

Joe:

Enjoy the down time. The top will always be waiting there for you to fix it! :P

Regards, Maurice.

[Jpeterson]

Dear Forum, In this message you advised the person to try to swithch the pushrods from one side to the other. I bought both large round pushrods new from a dealer and they are NOT the same. They each have a bend to them and are marked for the drivers and passengers side. My question is for you top expert. Can you really change the pushrods from side to side? I have had many problems and have broken 4 of the pot aluminum arms that the pushrods attach to so it is certainly possible that I have the sides confused and have them backwards. Thank you, Jerry

[1schoir]

Dear Forum, In this message you advised the person to try to swithch the pushrods from one side to the other. I bought both large round pushrods new from a dealer and they are NOT the same. They each have a bend to them and are marked for the drivers and passengers side. My question is for you top expert. Can you really change the pushrods from side to side? I have had many problems and have broken 4 of the pot aluminum arms that the pushrods attach to so it is certainly possible that I have the sides confused and have them backwards. Thank you, Jerry

Jerry:

The reason for the confusion is because, in this thread, we are referring to the pushrods that operate on the canvas top (with the plastic ball cups on one end) and you are referring to the "hydraulic" pushrods that operate on the clamshell (these hydraulic pushrods actually have a large spring inside of them, but look like hydraulic cylinders on the outside).

The pushrods that operate on the canvas top are interchangeable, left to right.

The "hydraulic" pushrods that are operate on the clamshell are NOT interchangeable, and are different for the left and for the right side.

Take a look at the parts that you bought new from the dealer and you should use them as follows:

Part # 986 561 579 00 LEFT SIDE (driver's side)

Part # 986 561 580 00 RIGHT SIDE (passenger's side)

Regards, Maurice.