Body - Convertible Top is Hard to Close

NUMBER: 23-019-05 REV. A

GROUP: Body

DATE: December 13, 2005

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-019-05, DATED MARCH 16, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.

SUBJECT:
Convertible Top Difficult To Close

OVERVIEW:
This bulletin involves replacing the pivot bolt at the front bearing point of the over center linkage and if necessary, the convertible top second rail and main guide rod.

MODELS:

2005 (ZH) Crossfire Roadster

SYMPTOM/CONDITION:

The customer may describe that the convertible top is difficult to close (pull the top down to the header).

DIAGNOSIS:

If customer describes the Symptom/Condition, perform the Repair Procedure.

NOTE:
It is no longer necessary to replace the entire convertible top frame when servicing the second rail and main guide rod. The second rail and main guide rod are available as service parts.





PARTS REQUIRED:

REPAIR PROCEDURE:

NOTE:
During the following procedure, the hydraulic system will loose hydraulic pressure after approximately 10 minutes. To avoid this momentarily cycle the convertible top switch up for an instant every 8 minutes.





1. Lower the convertible top to the repair position (Fig. 1).





2. On the left side of the vehicle, remove the header bow weatherstip up to the point shown (Fig. 2).





3. Remove the protective tape covering the cutout in the convertible top frame at the front bearing point of the over center linkage (Fig. 3).





4. Remove the retaining clip from the pivot bolt at the front bearing point of the over center linkage (Fig. 4).





5. Remove the pivot bolt at the front bearing point of the over center linkage (Fig. 5).

6. Install one of the new elastollan pivot bolts, from the service kit p/n 05191716AA, in the convertible top frame and install the retaining clip.





7. Install one of the new pieces of protective tape included in the service kit over the cutout in the convertible top frame at the front bearing point of the over center linkage (Fig. 6).

8. Install the header bow weatherstrip.

9. Repeat Step # 2 through Step # 8 on the right side of the vehicle.

10. Raise the convertible top to the closed position.

11. Is the convertible top still difficult to close?

a. Yes >> go to Step # 12.

b. No >> repair is complete. Return the vehicle to the customer.

12. Replace the convertible top frame second rail and main guide rod on both sides of the convertible top frame. Refer to the detailed removal and installation procedures available in TechCONNECT, under: Service Info, 23 - Body, Convertible Top, Rail, 2nd Rail and Main Guide Rod.

POLICY:
Reimbursable within the provisions of the warranty.




TIME ALLOWANCE:





FAILURE CODE:

Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.