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Thread: Convertable roof not locking at left side

  
  1. #1
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    superocket's Avatar
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    Cool Convertable roof not locking at left side

    Hi all,
    2002 Mk4 Cab
    The left hand (pasenger side) roof to windscreen lock looks like its not operating, ie it will not pull down on that side. I've had a look in and it looks like the black plastic block that runs on the worm drive is broken.
    Am i on the right track? If I am does anyone know a part# or name, my Holden dealers here in Australia dont know their A from their E . They just scratched their heads, if it's not a V8 ute they dont want to know
    Please help I need my roof working here in sunny Oz

    Regards
    Clive

  2. #2
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    superocket's Avatar
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    Answering my own question just incase its of use to anyone else.
    40 odd views and it still takes an aussie to answer the question about a euro car!!!
    to get plastic cover off
    Open roof till it points straight up (1/2 way)
    prop up rear cover as it will close by itself after a bit.
    use a rope to tie the roof forwar to the front wheel as it will start to fall back after a bit.
    Undo 2 small straps on the inside that hold the headlining down(tamper proof screws)
    Using a stumpy phillips reach between the headlining and the roof and remove 9 screws
    remove 4 screws from front edge
    .... remove plastic cover..... slowly mine was stuck to the headlining a bit.

    onto the real problem.........
    remove latch mech to get at broken plastic block
    undo ball joint at end of arm that goes back into roof
    on left hand unit undo sensor plug
    pull flex drive rod from centre holder then keep pulling to flex out of spline drive at each end.
    undo 4 tamperproof bolts and remove unit....

    now the bit I did to save $1500 a side.
    .. if the block is broken reasemble with epoxy glue using vice grips as clamps.
    the plastic block is molded onto the metal arm, inside there are two holes in the metal bars.
    you will see them when you look down the crack. (Mark before you glue back together)
    use a 1/8 long series drill and drill through the block going through the holes coming out in the 2 pockets between the 3 gusets
    insert 25mm x 1/8 metal thread with washers (4 as 25mm is a smidge long)
    nut on, down the pocket with another washer. tighten
    I then filled the pockets with epoxy to strengthen and lock in nuts

    refit units only lightly
    refix shafts
    refix arms to ball joints
    replug sensor
    close roof
    tighten 2 visable bolts
    open and tie with rope etc.
    tighten other 2 bolts
    refix plastc cover

    My righthand one was starting to crack too so I bolted that one too (no glue)

    $3000.00 saved!!!!!!!!!!!!!!!!!!!!!!!!!!!!

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    bozblakturbo's Avatar
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    Thanks for this post super rocket, I have just used it and found your instructions to be fantatsic! Sadly it doesn't look like my plastic blocks are going to hold. I have managed to close the roof so I can drive the car, but the motor seems to put too much pressure on them and they are already showing signs of cracking again.

    My astra is my daily deriver so I'm not too dissapointed the roof is going to have to stay closed for the time being, but i'm not looking forward to the reality of trying to source new parts.

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