Body - Convertible Top Rear Window Separation
911 (996)4/05
Binder - 6, Body Equipment
4/12/05
This bulletin replaces bulletin Group 6, # 3/04, dated 6-25-04.
Convertible Rear Window Bonding Loose
Vehicle Type:
911 Carrera Cabriolet (996)/911 Carrera 4 Cabriolet (996)
Model Year:
1999 (X) - 2001(1)
Concern:
Bond in the area of the flexible rear window to the convertible-top covering.
Information:
Defects (optical conspicuousness, leaks, loose bonding points) that indicate the bond in the area of the rear window to the convertible-top covering has become loose, it is generally required to check which bonding points have separated prior to performing any repairs.
Depending which bonding points are damaged, either the bond of the flexible rear window must be re-welded or the flexible rear window must be replaced, or the convertible-top covering must be replaced by the now available convertible top covering with sewn-in flexible rear window.
Note!
The convertible top covering with sewn-in flexible rear window can be identified by a seam encompassing the flexible rear window which is visible externally on the convertible top covering.
Parts Information
Work Procedure:
- Check bonding point in the area of the flexible rear window to the convertible-top covering.
- Determine the required repair measures.
1. Remove headliner, see 911 Carrera (996) Workshop Manual, Group 7, 70 84 19 - Removing and installing Cabriolet headliner - up to model year 2001 - as of MY 1998.
2. Check bonding points in the area of the rear window to the convertible-top covering.
2.1 Lift convertible-top covering in the area of the flexible rear window's bonding from the outside and check whether the bonding seam of the flexible rear window (see Figure 1, Item A) has detached from the convertible-top covering (see Figure 1, Item B) in one or more places.
2.2 On the inside of the convertible-top covering, check whether the bond of the fold (folded edge of the convertible-top covering, (see Figure 2, Item A) has detached from the bonding of the convertible-top covering (see Figure 2, Item B) in one or more places in the area of the rear window inset.
2.3 On the inside of the convertible top covering, check whether the bond of the zipper (see Figure 3, Item A) for fixing the flexible rear window (see Figure 3, Item B) has detached on one or more places from the fold of the convertible top covering (see Figure 3, Item C).
3. Determine the required repair measures.
3.1 If the bonding seam of the flexible rear window (see Step 2.1) has only detached from the convertible-top covering in one place, the area of detachment is no longer than 10 mm and no other bonding points on the Figure 3 inside of the convertible-top covering (see Steps 2.2 and 2.3) are loose, the bonding of the installed flexible rear window is to be re-welded, see Step 4.
If the loosened bonding seam of the flexible rear window can no longer be connected to the convertible-top covering through re-welding, the rear window must be replaced see Step 5.
3.2 If the bonding seam of the flexible rear window (see Step 2.1) has detached from the convertible-top covering over an area longer than 10 mm or has detached in several places and there are no more loose bonding points on the inside of the convertible-top covering (see Steps 2.2 and 2.3), the flexible rear window must be replaced, see Step 5.
3.3 If the bond of the fold (see Step 2.2) and/or the bond of the zipper (see Step 2.3) has detached, the convertible top covering must be replaced by the convertible top covering with sewn-in flexible rear window, see Step 6.
4. Re-welding the bonding of the flexible rear window.
Attention!
Defective bond if the cooling time after welding is not adhered to.
> Always observe at least 20 minutes of cooling time after every welding.
Leave the required tools fitted to the convertible-top covering during this time.
4.1 Re-weld bonding.
Note!
Procedure for re-welding the bond of the flexible rear window is identical with the procedure for installing the flexible rear window, see 911 Carrera (996) Workshop Manual, Group 6, 64 85 19 - Removing and Installing Cabriolet Flexible Rear Window.
4.2 Install headliner, see 911 Carrera (996) Workshop Manual, Group 7, 70 84 19 - Removing and installing Cabriolet headliner - up to model year 2001 - as of MY 1998.
5. Replace rear window.
5.1 Replace rear window, see 911 Carrera (996) Workshop Manual, Group 6, 64 85 19 - Removing and installing cabriolet flexible rear window.
5.2 Install headliner, see 911 Carrera (996) Workshop Manual, Group 7, 70 84 19 - Removing and installing Cabriolet headliner - up to model year 2001 - as of MY 1998.
6. Replace convertible-top covering.
Note!
After the vehicle is converted to the convertible top covering with sewn-in flexible rear window, the sewn in flexible rear window can no longer be replaced separately when it is damaged. In case of repairs, the entire convertible top covering including the sewn-in flexible rear window must be replaced. The replacement part numbers listed in the parts information are available for this purpose.
6.1 Replace convertible-top covering, see 911 Carrera (996) Workshop Manual, Group 6, 61 28 55 - Replacing convertible4op covering with flexible rear window.
6.2 Install headliner, see 911 Carrera (996) Workshop Manual, Group 7, 70 84 19 - Removing and installing Cabriolet headliner - up to model year 2001 - as of MY 1998.
Reference
Disclaimer