Old Feb 3, 2014 | 12:37 PM
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g3air
Joined: Nov 2008
Posts: 106
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From: Punta Gorda, FL
Question "Rebuilding the convertible top hydraulic system"

EDIT 8 April 2014: see the bottom of this post for a summary

OP: The top on our 2005 Crossfire has worked well since we bought the car new in late 2004. We have kept the car in south Florida since new. Other significant maintenance has been limited to replacing the (crazed) headlaight assemblies and replacing the convertible top (a couple of years back).

Just recently, however, the convertible top operation has become sluggish and will not operate without manual assistance (both to the top and to the tonneau cover operation).

I have read a number of posts regarding problems with the top operation. I don't believe any of the sensors are a problem, since the top does go down or up completely (with a manual assist) and locks or unlocks normally with the automatic window lowering or raising also functioning as they should. I hope I am not risking damaging the system by providing manual assistance to the top's operation.

The car battery is 16 mos old and shows 14V with engine running and 13V with engine stopped. The car starts quickly and normally.

There is no evidence of rust or debris in or around the convertible top components.

I would most appreciate any advice on further diagnosis or possible solutions for this problem.

Edit added: from reading further in a related thread, it sounds like I may be looking for rebuilding the top operation hydraulic cylinders - what do you think?

EDIT AT COMPLETION OF REBUILD/REPAIR:
After consultation and advice from forum members and Klaus Witte of Top Hydraulics, I decided to have the hydraulic pump and all seven power top system cylinders rebuilt. Although I have not worked on cars much, I am reasonably handy with tools. The job is not complex, but it is a long one and requires planning, patience and perseverance. I am confident that this is a "doable" repair for any reasonably "handy" crossfire owner.

Until a step-by-step do-it-yourself guide becomes available, you will need to have access to the Crossfire Service Manual (available online via this forum) and consult this thread for tips and ideas along the way. Tools required are pretty straight forward but of course bolts etc. are metric and there are some torx screws as well. Spanners and a ratcheting socket wrench with short extension are handy, as is a variable speed electric drill. You will also need a rivet gun and some rivets (aluminum 1/8" dia 1/16" - 1/8" grip range and 5/32" dia 3/16" - 1/4" grip range). I had never worked with rivets before and had some uncertainty about that, but it turned out to be inexpensive and easy.

I received good advice and support from the forum and especially from Klaus Witte of Top Hydraulics. Top Hydraulics was kind enough to loan me a couple of replacements for the the two latch assemblies (they did not include the hydraulic cylinders) so that I could use the top manually while the cylinders were being rebuilt. Turn around time by Top Hydraulics for the rebuilds was very fast (same or next business day) with the majority of in-process time due to the US Postal service. I would estimate that you could accomplish this repair easily in less than a month, and likely in far less time, depending on your available time and prior DIY mechanic experience.

Lessons learned (there are other tips in the comments along with the step by step photos):
* The very small new o-rings (supplied by Top Hydraulics) that fit on the ends of the hydraulic lines when reinstalling are very delicate, I unknowingly damaged two of them on installation and it caused leaks that I had to go back and fix later.
* Be careful to disconnect the negative lead to the battery as specified in the Service Manual before you work on the top.
* It is important to make sure the hydraulic pump reservoir is properly filled when all is reinstalled. It is likely you will need to manually exercise the top to get the hydraulic fluid back into the system and then check the level again.
* Never get in a hurry and if something is not going right, step back for a while, get advice and only then reapproach.

Approximate cost of this project:

Top Hydraulics
Pump rebuid $465
Cylinders (7) rebuild $760

USPS Postage $ 55

Additional tools; hardware $ 25

TOTAL $1,305

This compares to my guestimate of what a dealer would charge at likely $8,000 to $10,000. I know for a fact the dealer here wants $4,310 just for the price of a new pump!

My wife is very happy (it's her car, but she lets me drive it lol)
 

Last edited by g3air; Apr 9, 2014 at 01:33 AM.
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