2000S top problems - stuck in up position, one side will not work

[wulabs]

I'm so unlucky! 3rd car problem within a month! At this rate I will be struck by lightning tommorow!

This time, my convertible is stuck in the up position, the right side flap doesn't want to raise so my top can come down.

The left side of the clam shell can open a gap up to 12 inches high, while the right side stays in the normal down position. I didn't try opening any further for fear of breaking the clameshell thing.

I briefly looked under the clam shell, there is an arm (looks like a 'V' or 'Y' or a seesaw" which is at a 30 degree (from horizontal) angle on the left side of the car, and the one on the right side is still at 0 deg horizontal. So it would seem like the motor for the right side is broken. (I believe the motor drives this 'Y' piece to rotate, but i'm not sure.).

Another diagnosis, when operating the switch, sounds like motor sounds from both left and right sides...which indicates the transmission/motor for both sides are still working.

If somebody else has had similar problems, please email me WULABS@GMAIL.COM or post here. I need to order parts soon. I am located in Palo Alto.

I am planning on going through the forums to figure out how to transform my car into a manual convertible...better than a broken auto convert....until I figure out what the *#%@ is broken. I then plan on doing a manual repair myself.

Pictures here:

http://www.wulabs.org/jack/car/top/

[wulabs]

Looks like I have to do this (thanks guys for the guides and etc):

1) open clam shell, prop the stuck side open with towels.

2) remove clips on left and right sides, which attach the pushrod to the rear of the shell

3) use flathead to remove red ball joints

4) diagnose problem after shell is removed.

I plan on using the car in manual top mode for a little while until I figure out what needs to be replaced. Too bad its still raining in NoCal!

[Tool Pants]

Separate the joints for the black push rods. Then you lift up the clamshell to the full open position. When the clamshell is up remove the brass colored clip for each push rod and remove the rods from the car. Then disconnect the red plastic joints.

You will now be able to operate the top manually. To straighten the clamshell so that it will close get 2 people and tweat it back into shape. Search the top section as I have a picture of 2 mechanics doing this.

Most likely you have a broken drive cable.

If you need help you can bring it to my office in San Jose near the Arena.

[mark in sunnyvale]

Let me know if you guys need help. I can stop by Jeff's office as well. Jeff will not let me touch his car though, he thinks I forgot how to synch the transmissions. :-) I guess you can be the guinea pig so I can prove him wrong. hehe.

-Mark

Edited April 8, 2006 by mark in sunnyvale

[wulabs]

Hey guys,

I spent a few hours trying to release the black rods but to no avail.

I was able to get the clip (on one end of the black push rod) off on the left side (the working side). The right side of the car is a different matter. I was able to get the clip bent so its not locked into place, but the force on the clip is so high that I am unable to make the clip budge and slip off.

The shelf is IN my car and I have no way of getting it out, it makes working from the inside terribly difficult.

From the inside, I tried using a flathead to pop off the ball joint on the right side black rod, but to no avail.

Can somebody help me try to get the right rear black rod off? The clamshell is shut on the right side, and I can lift it up for about 2-3 inches of clearance but thats about it.

I'm in Mountain View. My email is WULABS@GMAIL.COM. I work during the day time...

As I mentioned earlier, the V itself is not turning on the right side, which leads me to believe the right side motor is broken.

-Jack

[Tool Pants]

Jeff will not let me touch his car though, he thinks I forgot how to synch the transmissions. Mark

You did touch my top. :P

[0586slb]

As I mentioned earlier, the V itself is not turning on the right side, which leads me to believe the right side motor is broken.

There is only one motor that does both sides. If you peer into your partially open clamshell, its right in the middle (just forward of the brake light) and has a bowden cable coming out of each end - one for the left side and one for the right. Keep searching in the 'Boxster Top Issues' subforum because you will be able to remove the cable and spin the inner to releive the pressure on the right side.

[wulabs]

Mark and a friend were able to help me out over the weekend.

it took a long time to try to remove the black rod on the stuck side (about an hour?!?!)

We eventually got in from the inside, used pliers, and yanked the clip off.

In the process we also took off the broken cable (the cable connection to the motor had snapped off).

Yes I have the upgraded cables in my 2000 S. The cable is "stranded" rather than "solid", which Mark remarked as being the first time he has ever seen that.

We were able to put a drill to the cable and spin it just a lil bit.

Another note, on 2000 and above, there is a plastic covering which extends further down than pre-2000 models which makes it VERY difficult to get any leverage on the black rod when trying to pop it out.

I will post pictures once I get around to it. You can also email me and I can send them to you.

Current status is:

My top is in manual mode (manual mode ain't bad, since I have to chop the back window anyways!) until I get the replacements and fix the mechanisms.