New to me a 2004 Z4 2.5 auto. Top does not work, is stuck in the up position. I removed the cover that allows access to the locking motor and removed the motor and discovered the nylon gear that moves the metal gear that is connected the the left and right flexible shafts was split into two pieces. I ordered a replacement but before installing the new parts I attempted to turn the right side flex shaft by hand and it will not move. I used the old metal gear and a pair of pliers and cannot get the shaft to turn, seems to be jammed. I do not want to install the new parts as I fear it will just crack the new gear. What could be preventing the flexible shaft from turning?
top problem, help
- Thread starter rgmrgm
- Start date
I think I have identified the problem but not the solution. The top latch on the right side has a micro switch to stop the latching motor when the top completes the closing cycle. If that switch does not do its job the latching motor will continue to turn which over tightens the latch and causes the nylon gear to fail. I am still trying to figure out how to break loose the overtightened latch. I have tried to use the flexible shaft and pliers but because the shaft is flexible it won't apply the initial torque to break it loose. Any suggestions?
Have you tried using the manual cranked Hex key that should be in the tool kit to release the locks?
Remove the central plastic cover at the top of the windscreen and use the Hex key by inserting it and turning it clockwise (to the right) to unlock the catches. The handbook describes how to lock it using the key by stating insert the Hex key and turning it anti clockwise (to the left) so I assume it will also unlock using the key as described.
Found this on another thread explaining how to unlock the roof and use the manual release in the boot for the hydraulic part of the set up.
Emergency closing / emergency opening
In the event of failure of electrical and/or hydraulic functions, the top can be opened and closed using emergency unlocking/locking systems.
Emergency closing:
In the luggage compartment on the left-hand side below the convertible top compartment floor, pull out the plastic ring attached to a Bowden cable as far as it will go.
With a 90-degree turn, lock the plastic handle in this position.
In the hydraulic unit, a short circuit is enabled, making it possible to open and close the folding top by hand.
Pull the handle of the Bowden cable in the rear panel of the luggage compartment.
The interlock in the convertible top compartment is released.
Move the top forwards by hand until it reaches the cowl panel.
Take the Allen key from the on-board toolkit.
Remove the plastic panel from the front roof brace.
Insert the Allen key in the uncovered internal hexagon.
Lock and unlock the cowl panel lock by turning the Allen key.
Take out and replace the Allen key.
Emergency opening:
Perform steps 1 and 2 as well as 5 to 7 from 'Emergency closing'.
Unlock and open the cowl panel lock by turning the Allen key.
Take out and replace the Allen key.
Move the top backwards until it reaches the convertible top compartment
Remove the central plastic cover at the top of the windscreen and use the Hex key by inserting it and turning it clockwise (to the right) to unlock the catches. The handbook describes how to lock it using the key by stating insert the Hex key and turning it anti clockwise (to the left) so I assume it will also unlock using the key as described.
Found this on another thread explaining how to unlock the roof and use the manual release in the boot for the hydraulic part of the set up.
Emergency closing / emergency opening
In the event of failure of electrical and/or hydraulic functions, the top can be opened and closed using emergency unlocking/locking systems.
Emergency closing:
In the luggage compartment on the left-hand side below the convertible top compartment floor, pull out the plastic ring attached to a Bowden cable as far as it will go.
With a 90-degree turn, lock the plastic handle in this position.
In the hydraulic unit, a short circuit is enabled, making it possible to open and close the folding top by hand.
Pull the handle of the Bowden cable in the rear panel of the luggage compartment.
The interlock in the convertible top compartment is released.
Move the top forwards by hand until it reaches the cowl panel.
Take the Allen key from the on-board toolkit.
Remove the plastic panel from the front roof brace.
Insert the Allen key in the uncovered internal hexagon.
Lock and unlock the cowl panel lock by turning the Allen key.
Take out and replace the Allen key.
Emergency opening:
Perform steps 1 and 2 as well as 5 to 7 from 'Emergency closing'.
Unlock and open the cowl panel lock by turning the Allen key.
Take out and replace the Allen key.
Move the top backwards until it reaches the convertible top compartment
I finally got the top to release. I removed the top latching motor and used pliers on the flexible shafts. The drivers side turns easily but the right side was very difficult but eventually released. Next step is to remove the right side latch and see why it is so difficult to turn. That is for another day