Originally Posted by
g3air
Given the satisfactory level of fluid in the reservoir, leakage (even though there is some seepage) is likely not the culprit. Checking other cylinders for seepage does not seem to be a promising diagnostic path.
My (admittedly novice) opinion for the most likely suspect is the hydraulic pump, since the faltering performance of the top-up or top-down operation seems irrespective of which phase the top is in or which hydraulic cylinders are being used.
Any further thoughts?
g3air, do not despair!
The fluid level in your pump p/n 5142638AA is high enough. You are down to two possibilities, and you can probably deal with this yourself:
1) An internal bypass in one of the two locking cylinders (Rear Bow Lock Cylinder 05142957AA or Tonneau Cover Latch Cylinder 05166559AA), or
2) The pump not being able to create enough flow under pressure.
It is much more likely that the pump is the culprit. The good news: Top Hydraulics offers a rebuild service for the pumps:
Chrysler Crossfire Hydraulic Pump Rebuild/Upgrade
The pump should be producing about 2000 psi when turning in one direction, and some 1700 psi in the other direction. There is a pressure port on the pump, but checking that kind of pressure off a metric port is a pretty specialized task. I would suggest that you send us the pump and we check it out. There will only be a nominal testing fee if the pump is performing well and does not need a rebuild.
To remove the pump, you need to make enough room for access, disconnect the wiring harness, disconnect the hydraulic lines, and unbolt the pump from the chassis. Disconnecting the hydraulic lines requires only that you unbolt the manifold plate on top, which holds all the hydraulic lines, and then pull up a little on each hydraulic line individually. The hydraulic lines will stay within the manifold plate - they are retained by small snap rings, and they will not get mixed up. Before sending the pump to Top Hydraulics, make sure to drain the fluid. You would not want fluid to soak your parcel. Wrap the pump inside a garbage bag or two, buffer the parcel well inside (so that the reservoir and solenoids won't get damaged during shipping), and tape up well on the outside. Top Hydraulics uses USPS Priority Mail Flat Rate Boxes to ship pumps. I would recommend double boxing (squeezing one box of the same size into another).
The top can still be moved and locked manually without the pump in place, but there will be some fluid coming out of the disconnected hydraulic lines once you move any hydraulic cylinder.
I mentioned the possibility of an internal bypass in one of the locking cylinders before, so I will elaborate a little on that. Most modern convertible top systems are designed such that the locking cylinders always have pressure on one side when the pump is running. Pressure to the top of the cylinder will make the lock latch if the locking mechanism allows it, and pressure on both end will make the lock unlatch. The lock unlatches with pressure on both ends, because there is more cross section for the hydraulic fluid to push against on the bottom of the piston than on the top. Both the tonneau cover lock and the rear bow lock in the Crossfire are designed such that they cannot close unless the prong from the tonneau cover or the rear bow (respectively) have been received within the locking mechanism. This setup saves two valves on the pump. Having said all this, internal bypasses on the Crossfire's locking cylinders are extremely rare - I only brought this up because it is theoretically possible.
I will elaborate some more on cylinder leaks in a separate post.
Klaus
Top Hydraulics | Rebuilt and Upgraded Convertible Top Cylinders, Pumps, Hydraulic Lines - Top Hydraulics, Inc