Body - Convertible Top Torn At Lock/Right Rear
09-033August 1, 2009
Applies To:
See VEHICLES AFFECTED
Convertible Top Is Torn at the Lock Handle and/or the Right Rear (Supersedes 09-033, dated May 21, 2009, to revise the information marked by the black bars and asterisks)
*REVISION SUMMARY
^ Under PARTS INFORMATION, elastic bands and pop rivets were added.
^ A REQUIRED MATERIALS section was added.
^ Under WARRANTY CLAIM INFORMATION, a labor operation number was added to the chart.
^ Under REPAIR PROCEDURE, steps 6 thru 12 were added.*
SYMPTOM
The convertible top is torn at one or both lock handles and/or the right rear area.
PROBABLE CAUSE
There is a rough surface on the lock handle and/or the right rear frame hinge.
VEHICLES AFFECTED
For the following VIN ranges, the convertible top may be torn at the right rear area:
2005-07 S2000 - ALL
2008 S2000 -
From VIN JHMAP...85000001 thru
JHMAP....8S002446
2009 S2000 - ALL
For the following VIN ranges, the convertible top may be torn in the front area:
2005-09 S2000 - ALL
CORRECTIVE ACTION
Replace the convertible top cloth and one or both lock handles, and remove any rough spots on the right rear frame hinge.
PARTS INFORMATION
*REQUIRED MATERIALS
White Lithium Grease Spray (One can repairs about 45 vehicles):
P/N 08732-0005, H/C 2963718*
TOOL INFORMATION
Eye protection
4 mm drill bit
Drill
Body vise grip pliers or pop rivet gun
WARRANTY CLAIM INFORMATION
In warranty:
The normal warranty applies.
Failed Part: P/N 86310-52A-J03
H/C 8800005
Defect Code: 07701
Symptom Code: 02602
Skill Level: Repair Technician
Out of warranty:
Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work.
REPAIR PROCEDURE
1. Remove the convertible top:
^ Refer to page 20-41 of the 2000-2009 S2000 Service Manual, or
^ Online, enter keyword CLOTH, and select
Convertible Top Cloth Replacement from the list.
2. With the convertible top assembly out of the vehicle, use a white marker to draw a circle around each of the 11 rivets.
3. Pull the rain rail up, and turn it inside out.
4. Drill out the rivets on the rain rail with a 4 mm drill bit, then remove the rail.
5. Pry apart the rivets that attach the rain rail to the cloth.
^ If the cloth is torn at or near one of the lock handles, go to step 6.
^ If the cloth is torn at the right rear area, go to step 15.
*6. Grasp the second rib on the convertible top and pivot the second rib toward the rear, then forward again.
^ If the second rib does not pivot easily, go to step 7.
^ If the second rib pivots easily, go to step 8.
*7. Remove the covers from the left and right pivot point of the second rib, then lubricate the pivot points with white lithium grease spray.
^ If the second rib still does not pivot easily, replace the damaged parts.
^ If the second rib now pivots easily, reinstall the pivot covers, and go to step 8.
8. Using a cutoff wheel or a drill with a bit no larger than the rivet (3.6 mm), cut the heads off of the eight pop rivets that secure the two elastic bands to the second and third ribs of the convertible top.
9. Remove the four plates that secure the elastic bands, then remove the elastic bands.
10. Continue to drill or cut off the remaining portions of the rivets. Be careful not to make the hole in the rib any larger, or the new pop rivet will not hold securely.
11. Remove the rubber plugs from the ends of the second rib, and shake the rib to remove the old pop rivets. Reinstall the rubber plugs.
12. Install the new elastic bands with the new plates, and secure them with new pop rivets.*
13. Inspect the lock handle for a rough surface.
^ If there is a rough surface, remove the lock handle on the affected side(s) as shown.
^ If the lock handle does not have a rough surface, go to step 15.
14. Install the new handle(s) in the reverse order of removal, and apply multipurpose grease to its springs and moving parts. Then, go to step 18.
15. Locate the burrs at the right-rear of the frame hinge, then use a file to remove the burrs and any rough areas.
16. Remove all metal particles from the hinge and the frame.
17. Prime the filed area with a commercially available primer spray paint, and allow it to dry. Finish the primed area with a flat black spray paint.
18. Reinstall the rain rail with 11 new brass rivets or with 11 commercially available pop rivets and washers. If using pop rivets, make sure the crush end of each rivet is facing the rear of the vehicle when the rain rail is in place.
19. Reinstall the convertible top and all other removed parts.
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