Convertible Top - Windscreen Folds Down While Driving
ACCESSORIESAX003-06
Title:
WIND SCREEN DEFLECTOR
PERFORMANCE IMPROVEMENT
Models:
'05 - '06 Solara Convertible
March 27, 2006
Introduction
Some 2005 - 2006 model year Solara Convertible customers have complained that the wind screen deflector will intermittently fold down while driving. To correct this condition, the Solara wind screen deflector performance can be improved by replacing the hinge parts and modifying the tonneau cover. Following the instructions in this bulletin will guide you through completing this process.
Applicable Vehicles
2005 - 2006 model year Solara Convertible vehicles.
Parts Information
Recommended Tools & Material
Warranty Information
Applicable Warranty:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific complaint.
Repair Procedure
Order part number PT906-06040-FF and use the following instructions to install the improved components for the hinge of the wind screen deflector.
1. Disassemble wind screen.
CAUTION:
Be sure to wear eye protection.
A. Remove the wind screen from the vehicle.
B. Place the wind screen on a clean work bench. Be sure to protect the wind screen from being scratched or damaged.
C. Fold down the LH hinge that has the detent function (driver's side hinge) (Figure 1).
D. Using the small blade screwdriver, carefully push back the plastic cylinder against the spring pressure far enough to insert the washer to hold it open (Figure 2).
E. Insert the washer to hold the cylinder open (Figure 3).
F. Remove the C-clip holding the hinge pin (black) in place (Figures 4 and 5).
G. With the C-clip removed, use the small blade screwdriver to initially push the hinge pin out (Figure 6).
H. Using the vise grip, pull the hinge pin completely out (Figure 7).
CAUTION:
Be careful with the cylinder spring as it may come out with force under the spring compression.
I. Take the hinge assembly completely apart removing the screw from the bottom of the hinge and remove the wind screen metal blade (Figure 8).
a. Retain the following parts for reinstallation:
^ D - Hinge pin (black)
^ H - Metal blade
^ I - Screw
b. Discard the following parts as they will be replaced with new kit parts:
^ A - Plastic cylinder
^ B - Large spring
^ C - C-clip
^ E - Detent pin
^ F - Detent springs
^ G - Plastic housing
2. Install rubber stopper.
The following steps (2A through 2E) show how to install the rubber stopper into the LH side (driver's side; hinge side) bottom of the frame (Figure 9).
A. Using a paint pen or marker and a measuring device:
^ Mark a point on the LH (driver's side; hinge side) bottom side corner of the frame 10 mm (0.4 in.) from the outer edge (Figure 10).
B. Place a drill stop on the 1/8" drill bit 10 mm (0.4 in.) from the tip of the drill bit (Figure 11).
C. Center punch and drill the marked point with the 1/8" drill bit. Drill the hole to a depth of 10 mm (0.4 in.). Be sure to drill the hole perpendicular to the surface of the hole location.
D. Dab a small amount of silicon sealant on the stem of the rubber stopper (Figure 12).
E. Install the rubber stopper into the drilled hole in the frame (Figure 13).
3. Reassemble wind screen using upgraded parts.
CAUTION:
Be sure to wear eye protection.
A. Exploded view of hinge shown with upgraded parts (Figure 14).
a. Original parts:
^ D - Hinge pin (black)
^ H - Metal blade
^ I - Screw
b. New kit parts:
^ A - Large cylinder
^ B - Cylinder spring
^ C - C-clip
^ E - Detent pin
^ F - Detent springs
^ G - Plastic housing
^ J - Frame screw & washer
^ K - Small cylinder
B. Open the grease package and using the grease applicator, apply a small amount of grease to the bottom of the frame base (Figure 15).
C. Install detent springs into the plastic housing (large springs are placed on the inside and the small springs are on the outside) and place the detent pin on top of the detent springs (Figure 16).
D. Slide the grooved side of the hinge pin (black) in through the new small cylinder. The hinge pin will hold the detent pin and springs all together.
E. Reinstall the hinge assembly to the wind screen frame.
a. Insert the NEW cylinder spring into the large cylinder.
b. Assemble the spring and cylinder into the frame base and compress the cylinder while installing the hinge assembly (Figure 17).
F. Once the hinge is in place, slide the pin through capturing both the small and the large cylinders. Leave 6 - 7 mm (0.24- 0.28 in.) of the pin sticking out from the side of the hinge assembly in order to install the C-clip.
G. Using the large screwdriver, compress the large cylinder into the frame base exposing the C-clip groove on the pin (Figure 18).
H. Grab the C-clip with the needle nose pliers and reinstall the C-clip on the hinge pin.
I. Align the hinge assembly with the frame base and push the pin completely through the assembly so the pin is flush with the outside of the hinge assembly (Figure 19).
4. Modify tonneau cover.
The following steps (4A through 4H) show how to install the frame screw and washer through the tonneau cover leather (Figure 20).
A. Using a paint pen or marker and a measuring device:
a. Mark a point on the bottom LH (driver's side; hinge side) corner of the frame 10 mm (0.4 in.) from the bottom of the frame. Center the mark in the middle of the frame (Figure 21).
b. Mark a point on the bottom RH (passenger's side; ball-socket) corner of the frame 20 mm (0.8 in.) from the bottom of the frame. Center the mark in the middle of the frame (Figure 22).
B. Place a drill stop on the 1/8" drill bit 15 mm (0.6 in.) from the tip of the drill bit.
C. Center punch and drill each marked point with the 1/8" drill bit. Be sure to drill the hole parallel with the frame assembly (Figure 23).
D. Fold and wrap both front corners of the tonneau cover around the frame corners over the top of the drilled holes and snap into place (Figures 24, 25, and 26).
E. Slide the tonneau cover corner down on the outside of the frame enough to expose the drilled hole (Figure 27).
F. Using a paint pen or marker, mark the leather in line with the drilled hole in the frame.
G. Unsnap the tonneau cover corner and drill the marked location on the leather with the 1/8" drill bit (Figure 28).
H. Install the frame screw and washer with the T20 Torx driver through the leather of the tonneau cover corner on both LH and RH sides of the wind screen and snap back in place (Figure 29).
5. Adjust wind screen width to vehicle width.
A. Loosen the screw at the bottom of the metal blade on the RH-side hinge.
B. Reinstall the wind screen metal blade to the bottom of the LH-side hinge and loosely install the screw (Figure 30).
C. The bar supporting the tonneau cover portion of the wind screen faces forward when placed in the vehicle. Install the wind screen into the vehicle by inserting the blades through the trim panel grommets.
D. Center the wind screen side to side in the metal blades and tighten the lock-down screws at the bottom of each metal blade.
E. Attach the hooks at the ends of the elastic straps to the underside of the rear seat belt bezel (Figure 31).
6. Drive vehicle and confirm repair. Confirm there are NO squeaks or rattles.