Top failure

[ravengolfer]

I am experiencing the following symptoms with my top:

1. The open top indicator remains lite all of the time

2. I am having problems get the top to move from a fully open or fully closed position. Once moving it operates normally.

I feel it is a micro switch failure, but cannot find the switch.

I tried to use ronbonner's "micro switch trouble shooting sequence" (posted under "Boxster Convert Top Won't go up Car on/Brake up. Swith does nothing" 26 May) for my 2000 Boxster and could not find the B pillar micro switch or the compartment lid (motor) micro switch.

micro_switch_troubleshooting.pdf

[ravengolfer]

Found part of my answer in this post:

Boxsternaut

Group: Moderators

Posts: 2,376

Joined: 19-June 03

From: San Jose

Member No.: 4

Wow, very good. CTS, the company that makes the top, should hire you. You are correct that the new style transmission has a microswitch. I pulled one out and it is in my fingers. I guess that is why the lever/microswitch above the top motor was eliminated when the new style transmission went into production.

You do need the after running time, the second or so the motor continues to run, when the top is down. This pulls down on the black rods attached to the clamshell so that the clamshell is held tightly to the body. The underside of .clamshell, in turn, has those 5 round rubber discs which clamp down on the canvas. Otherwise you would have rattle city from the top and the clamshell.

I thought the run time was controlled by the top relay/control unit and that there is some type of timer in it that allows to motor to run that extra second. Your device stops the power to the motor sooner than normal. Is that what it does?

Did you ever try another relay and see if the problem went away?

Attached thumbnail(s)

[Tool Pants]

I know a little about 1997 - 1999 tops but the drive changed in 2000 and in a prior post you said you have a 2000. We have not worked on a 2000 up because they don't have the problems the older models do. Therefore this may be a Peter question.

As you figured out you cannot find the compartment lid (motor) micro switch because that is only for 1997 -1999.

Some of the early 2000s had bad top relay/control units. But when they went bad the top would simply not operate. Just for grins take it out and see if it has a black dot on the bottom on the base where the pins are. Give it a tap and put it back in. If the light will still not go out them see if you can swap a relay from another 2000 -2004.

On a 1997-1999 when you open the top you must hold your finger on the button for a second or two, even when the clamshell is fully down, or the light will not go out. This allows the top motor to operate an extra second or so, and then something inside the top relay/control unit shuts off the light after the time limit is met. With that said, are you holding the button down long enough for the light to go out? You are not supposed to take your finger off the switch until the light goes out.

What do you mean there is a problem getting the top to move from fully open/close?

[ravengolfer]

I found the problem! There is a nylon gear in the transmission that cracked. This was not allowing the top to fully open or close. The part number for the transmission is 986.561.180.03. It looks like the gear is not replaceable without replacing the whole transmission. A new one is about $500.00 Can one find a used one anywhere?

[flewis99]

I'm coming in late for this concern, but my 97 Boxster top has failed in the down, or open position. The clamshell is locked down and can't be puled up manually. I do see that the plastic caps on the push rods are broken and I get a hard repeating thump when trying to get the top back up. I can't seem to find a way to release anything that may be holding the clamshell down. I have ordered replacement caps for the push rods, but how can I manually raise the top to keep from getting rained in?

[ironcfo]

I have a 1999 Boxster. When I try to put the top down the windows drop as usual but all I get is a click sound behind the driver compartment. Now the top light stays on. The micro switch by the roof latch seems to be working and I replaced the micro switch beneath the hand brake a few years ago. Any ideas?

Edited October 23, 2016 by ironcfo

[RFM]

The big relay, under the dash left side, wanted to cause problems in the circumstances as you mentioned.