Porsche 911 (996/997) Carrera Convertible Top Mechanism Repair

  • Source: PelicanParts.com
  • Models: Porsche 996 (1998-2005), Porsche 997 (2005-2012)
  • tools: Torx screwdrivers/sockets, Phillips screwdrivers, hex socket set

The convertible top on the Porsche Carrera is hydraulically actuated.

This means that rather than using the traditional approach of cable and pullies, the car uses a set of pressurized cylinders to both open and close the top. Over time, the system can leak or fail, causing your convertible top to get stuck in either the up or down position. In this article I will explain the basics of the system.

The basic operation of the system boils down to the use of two hydraulic actuators, mounted inside each rear interior panel. Each actuator is fed by the main system pump. If the system is low on fluid, it can operate loudly and cause the top to stop working. If you are having problems with your top, there is a chance you could just be low on hydraulic fluid. Sometimes simply adding fluid to the system can get it working again. Additionally, the fluid in the reservoir can go bad, especially if there are leaks or contaminants, causing the system to work harder.

Begin by moving the convertible top to the service position. This is where the front edge of the convertible top is about 12-15 inches from the top edge of the windshield. This is so you can keep the body flap open and also gain access to the pump. Once the top is in the service position, look under the rear window flap to find the guide cable connections. These are attached to the car with two ball joints (picture 1). The idea here is to keep the rear window flap down when the top is opening or closing. Pop both cables off the ball joints and fold the rear window flap up over the top.

Directly below, you'll see a carpeted area held in place with four plastic rivets. Pry the rivets out with a small screwdriver and carefully work the carpeting over the two large plastic blocks on either end. Once the carpet is clear of the blocks, pull the carpeting up and out of the car. You'll see the hydraulic pump for the system underneath. You'll also have access to the rear body flap motor as well as the DME computer and the relays. Locate the two hydraulic lines going out from the pump to the actuators. In between the lines on the pump, you'll see a hex plug. This is where you fill the system. Directly under the pump is the fluid reservoir. Shine a flashlight behind it to see the fluid level inside. The fill level line is right below the fill port plug. If you have determined that the fluid level is low, remove the hex plug and use a small syringe along with some plastic tubing to fill up the reservoir.

Another part of the system that can fail is the front latch mechanism on the center front of the convertible top. This motor assembly extends a hook out that latches the top against the windshield frame. If the motor inside fails, you can still manually open or close the latch. To access the latch assembly, pry the plastic cover off the latch mechanism from the front. Underneath you'll see the manual over-ride actuator and the mounting points for the latch mechanism. To open or close the latch, insert the 6mm hex key into the over-ride actuator and turn it counter-clockwise to close the latch (this is the same tool used to emergency open/close the entire top, located behind the rear seat panel) Turning it clockwise opens the latch. If you need to replace the entire latch mechanism, remove the four Torx bolts holding it to the convertible top and then remove the electrical connectors going to it. Installing the new latch mechanism is the reverse of removal.

If the convertible top cannot be opened using the switch, you can open it manually. This procedure is intended to be used only as a last resort as you can lose the reference points for the system to operate correctly, requiring the use of a Porsche factory computer to reset them. Begin by removing the rear panel behind the seats. This is held in place by two Philips head screws.

Once the panel is removed, you'll see the two access points for opening and closing the top as well as the tool stored on the bulkhead. For instructional purposes, we will assume the top needs to be closed. Begin by prying the circular covers off the roll bar bulkhead and insert the tool into the hex slot below. Now rotate the tool until both side flaps have been opened.

Now move back to inside the car. Locate the port on the right which turns the convertible body flap motor. Insert the tool and rotate it counter clockwise until the body flap is fully extended. Now insert the tool into the left side port and turn it counterclockwise one turn. This port is a pressure relief screw for the convertible top. Opening it allows you to grab the top and manually move it yourself. Grab the top in the middle and pull it up and over the car. Now use the manual over ride on the front latch mechanism to lock the top down.

Article Figures

Figure 1

Once the top has been extended into service position and the rear body flap is open, access the hydraulic pump by first prying the rear window guide cable ends off the ball joints on either side of the car.

Figure 1

Figure 2

Fold the rear window flap up and over the convertible top to access the area directly below. You can see end of the guide cables that have been disconnected here.

Figure 2

Figure 3

Pry out the four black plastic tabs holding the upper part of the carpet to the roll bar bulkhead.

Figure 3

Figure 4

Begin removing the carpet by stretching the carpeting over the black plastic block on either side of the car. Once free of both blocks, lift the carpet out of the car.

Figure 4

Figure 5

Shown here is the hydraulic pump that powers the whole mechanism. Over time, it may be necessary to add fluid to the reservoir below the pump. To add fluid, remove the fill port plug. Add hydraulic fluid until the level in the reservoir reaches the high mark which is located below the fill plug. Use a syringe with a long tube to both withdraw the old fluid from the reservoir and also add new fluid. Here you can also see the DME and the DME relays.

Figure 5

Figure 6

Shown here is one of the two hydraulic actuators used to both raise and lower the top. They are located behind each rear side panel. The actuators are mechanically linked to the convertible top frame, so that when the actuators expand, the top raises. Here you can see parts of the convertible frame.

Figure 6

Figure 7

The front latch at the windshield can also fail over time. However, you can also manually override the electric motor. Pull the cover off the front latch mechanism by pulling down on the plastic cover at the front. Shown here is the front latch assembly with the cover removed. In this picture, you can see the manual override port. Turning the 6mm screw inside counter-clockwise closes the latch, turning it clockwise opens the latch.

Figure 7

Figure 8

To remove the latching mechanism, remove the four Torx bolts holding the latch assembly to the front of the convertible top.

Figure 8

Figure 9

Once the front latch assembly has been removed from the top, squeeze the black tabs on both of the electrical connectors to disconnect them. Now you are ready to install the new latch assembly.

Figure 9

Figure 10

Access the manual over-ride for the top requires removal of the panel directly behind the upper rear seats. Fold the rear seats down and remove the two Phillips head screws holding it in place. Now pull the panel out of the car.

Figure 10

Figure 11

Once the rear body flap has been removed, you'll have access to manually lower or raise the top. Shown here is the bleed valve used to actuate the convertible top frame, the manual motor override for the rear body flap and the actuation tool stored on the bulkhead.

Figure 11

Figure 12

To manually open or close the top, you'll first need to use the tool to open the side flaps on the car. Rotate the tool counter-clockwise until the side flap is fully open.

Figure 12

Figure 13

You'll next need to open the body flap on the rear of the car. Insert the tool into the port on the right and turn the tool counter-clockwise until the body flap is fully extended. The left port on the car is simply a pressure relief valve for the convertible top pump. You'll need to open this port to allow the system pressure to bleed off. Turn the valve counter-clockwise one revolution. If the top is already closed, simply push it back until it folds back into the car by itself. If the top is already open, grab the top in the middle and pull it up and over until it is just nearly closed. Now use the front latch assembly over-ride port to close the top fully. Once closed, re-tighten the valve. Keep in mind that using this method of opening and closing the top may require you to reset the reference points in the system using a factory Porsche computer, such as a PS2.

Figure 13

Summary

This article covers the Porsche 996 (1998-2005) and 997 (2005-2012) Carrera convertible top mechanism. It includes:

  • Hydraulic pump operation and fluid maintenance
  • Hydraulic actuators that raise/lower the convertible frame
  • Front latch mechanism at the windshield
  • Manual override procedures for emergency top operation
  • Component locations and access methods
  • 13 detailed figures with explanations

Project time: ~3 hours

Original article source: PelicanParts.com