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• Project Time: 8 hours
• Tab: $100 to $ane,000
• Talent
• Tools: Ability drill

• Parts Required: Various components, depending upon what is damaged
• Operation Gain: Properly functioning top
• Complementary Modification: Replace rear window, upgrade height to glass window

The Boxster convertible superlative mechanism is used a lot, and is oftentimes exposed to a lot of stress and strain as a result.

Information technology's very likely that you volition experience a problem with the opening or closing of your elevation somewhere along the line: knowing what to supersede and fix is valuable information.

1 of the first things I installed in my wife'due south Boxster was the SmartTop controller that allows you to open and shut the roof with one-touch functioning (see Pelican Technical Article: Smart Top Roof Control Installation). This is a neat feature, except that there are no safeguards congenital into the unit. And so, if the top latch is not fully released and the roof catches on it as it is beingness automatically lowered, y'all can seriously impairment your roof. In my instance, I accidentally did this one mean solar day, and the resulting damage ended upwards including about 20 hours of work along with $1200 worth of parts (see the photos in this project). If y'all install one of those automatic controllers in your Boxster, merely beware of the potential impairment from the 1-touch operation button.

When compared to other convertible cars (similar the BMW 3-Serial), I find the blueprint of the Boxster roof to be relatively unproblematic. A single motor connects to two cables and drives a leveraged gear mechanism that raises the rear of the roof, so raises the rear convertible lid, and then folds and tucks the top away. When your roof is not opening or closing correctly, then one or more of the components in the mechanism are probably worn out or damaged. Follow the photograph array in this article to learn well-nigh each of these components and how to replace them.

The early on-fashion convertible top transmissions accept been replaced with a more than reliable later-style one. This can be installed in place of the early one, but y'all need to also supplant the standoffs with different ones specific to the late-style assembly.

Hot tip

Check over all components carefully " there may be some damage that is hidden

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Project Photos

Figure 1 This photograph shows some of the parts that you might need to repair your convertible superlative. A- Convertible tiptop motor (powers both left and correct sides at the same time). B- Ball pin pin (ii req) C- Control cable D- Improved transmission assembly (increases the leverage of the motor to elevator the pinnacle), left and correct required East- Control lever (attaches to the opposite side of the transmission assembly), 2 req F- Improved transmission associates standoffs. These are required in order to bolt the transmission assembly in the aforementioned identify that the old one fit, ii req G- Switch to notice closed position of the tiptop handle H- Bushing for convertible top push rod (item J), 2 req J: Convertible top push rod (pulls and pushes the top open up and closed), 2 req

Effigy ii This photo shows tremendous destruction on the left side of the convertible pinnacle motor associates. The bluish arrow shows the red plastic ball socket for the top assembly that has completely broken abroad. This normally would connect a pin ball pin that is located out of view about the greenish arrow. In addition, the mechanism for lifting the rear metal embrace has completely sheared off every bit well. The pivot ball pin (shown in inset) would normally be attached to terminate of the control lever (xanthous arrow), just due to the acme getting stuck, it has been broken off. In this case, the top manual, the lever, and the convertible height push rod needed to be replaced with new parts.

Figure three If your convertible height push rod has broken, and then you lot will need to replace it with a new i. Unfortunately, at the time of this writing, a new plastic brawl cup cease is only available by purchasing an entirely new rod (about $75). When yous get the new rod, line information technology upwards to the old ane, and brand sure that the ii are exactly the same length. Change the two aligning points on the rod if necessary. To install the rod dorsum onto the convertible top linkage, use a screwdriver wedged upward inside the mechanism to obtain the necessary leverage to snap it on.

Figure 4 To remove the convertible top transmission, brainstorm by removing the boomerang-shaped lever (left photograph). Using a 19mm socket and a breaker bar, you should be able to loosen the bolt and remove it from the transmission. In this particular case, the lever arm had bent and the transmission had as well broken. Pull dorsum on the foam sound slow fabric to reveal the convertible elevation transmission (right photo). 3 nuts attached to standoffs hold the manual in place.

Effigy 5 This photo shows the diverse steps involved with removing the transmission and disconnecting the cable. A- With the iii nuts removed, pull back on the transmission and split it from the side of the car. B- Loosen upwards the 4 basics on the behind of the transmission housing, just do not remove them. C- With plenty slack in the mechanism, carefully pull out the cable. D- The dark-green arrow shows one of the three standoffs that need to exist replaced if you upgrade to the later-style convertible transmission. Eastward- The afterward-mode transmission allows y'all to simply snap the cable in place without removing whatsoever screws. F- Shown here is the replacement, later-style transmission installed in place with the new longer standoffs.

Figure 6 To disconnect the cable from the motor assembly at the rear of the compartment, just remove the circlip (xanthous arrow), and pull out the cable. Replacement of the motor and/or switch are adequately like shooting fish in a barrel as well: just remove both cables, unplug the electrical connection, and unbolt the motor assembly. Unfortunately, at the time of this writing, the only way to replace this microswitch is to purchase the unabridged bracket associates (about $130 from Porsche).

Figure 7 The factory manuals recommend using a drill to move the cables while aligning the left and correct side, however, after repeatedly doing this many times, I discovered a short cutting. If yous disconnect one side of the cable to the motor, you tin so printing the roof up/down button for short bursts of time. This will move i side of the roof mechanism, but not the other side, allowing you to align one side with the other. For extensive movement of the convertible tiptop manual, I recommend using the cordless drill.

Effigy eight When all of your parts accept been replaced, you need to align the left and correct assemblies together. Proceed in mind that if something broke on your roof, then y'all might have aptitude some of the tracks for the rear comprehend or other important components of the mechanism. In other words, y'all may not be able to get the top aligned completely perfectly. The goal is to get the lever arms on both sides in the same position at the same fourth dimension. Mensurate the length from the lever arm to a reference point on the top of the car and compare it to the opposite side. Adjust one side of the mechanism by using the technique described in Photo 6 to match both the left and right side.

Got more than questions? Ask whatsoever of our automotive experts.

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Source: https://www.pelicanparts.com/techarticles/Boxster_Tech/71-BODY-Convertible_Top_Repair/71-BODY-Convertible_Top_Repair.htm

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