Complaints # 1 Through # 11
Complaint 1:Creaking and squeaking across entire width of the windscreen frame and at upper area of roof frame.
Cause:
The contact surface on the retaining strip is not flocked (a felt like covering that is applied during the manufacturing process of the retaining strip). Movement between the windshield frame seal and retaining strip will make this noise (A, figure 5).
Repair:
On hardtops without a flocked contact surface on the retaining strip, cover the area that contacts the windshield frame seal with a piece of Teflon tape. Cut a strip of tape 20 X 1,190 mm and place it on the retaining strip as shown by the A arrows in figure 5.
Note:
A Teflon strip must never be stuck on to a flocked retaining strip! Last step: put the hardtop on.
Materials
Complaint 2:
Rattling from the outer area of the windscreen frame and the roof frame at the top left or right hand corner.
Cause:
Movement between the hardtop and windscreen frame combined with play in the centering pegs (B, figure 6) in their supports in the windscreen frame.
Repair:
Adjusting the fit into the windshield
Remove the hardtop.
Remove the mount bolt covers and loosen the two bolts at each of the mounts (arrow a, figure 6) (use hex socket 4 mm /6.0 x 22).
Move the mounts forward, towards the passenger compartment (arrow b, figure 6). Figure 6 Pull the roof frame seal from under the mounts and lay it over the mounts (arrow in figure 7). Tighten and torque the bolts to 7 Nm (5.0 ftlb.).
Install the hardtop and check the absence of play by vertically shaking it with the doors open. If play is still present, apply a felt strip of 25 x 20 mm to the top of each support (arrow in figure 8).
Materials
Complaint 3:
Squeaking from the middle area of the windshield frame at the top.
Cause:
In the locking lever (C in figure 9) at the front, rubs in the guide slot of the locking hook.
Repair:
Open the locking lever and apply grease in the guide for the latch (arrow, figure 10).
If necessary, apply Teflon adhesive tape to trim contact point.
Materials
Complaint 4:
Squeaking from lateral area of the windscreen frame at the top.
Cause:
The sun visor in the raised position rubs against the stop buffer of the trim panel when the vehicle is driven.
Repair:
Apply lubricant (Krytox or Vaseline) to the stop buffer (arrow, figure 10).
Materials
Complaint 5:
Creaking from the hardtop trim panels (all).
Cause:
The trim panels or their fastening elements rub against each other and/or the hardtop.
Repair:
Remove the interior trim panels and insulate them by applying felt or foam rubber strips in the areas that contact other components.
Hardtop interior trim panels
The previous metal fastening clips (Figure 12) were replaced by new plastic fastening clips (999 507 764 40 - Figure 13).
The rear left/right hardtop latch covers (Figure 11, Item D) is an exception. Each of these have metal fastening clips.
During repairs, only plastic fastening clips (999 507 764 40 Figure 13) may be used for fastening the interior trim panels (Figure 11, Items E, F G)
Install plastic fastening clips (999 507 764 40 - Figure 13) without tricot tape
Note:
Always replace the two piece metal clips (a, figure 12) before reinstalling the trim panel back on the hardtop. Only use the yellow clips that are coated for noise reduction. After installing the new clips, you must cover them with a piece of tricot tape (b, figure 12).
5.1 Hardtop latch cover (D - left/right).
Cause:
Cover for hardtop latch (D - left/ right) is loose and/or damaged. Figure 13
Repair:
Remove hardtop latch cover (D - left/right). Unclip the cover at the fastening clip (Figure 14, arrow a) first and then pull it off.
Check the cover for loose bonds or other damage and, if necessary replace. New covers are delivered with metal fastening clips (Figure 14, Item a). Before fitting the cover, check whether all felt strips are present and undamaged (Figure 14, arrow b with dimensions). Replace damaged or missing felt strips.
If a cover that has been removed is re-fitted, the metal fastening clip (Figure 14, arrow a) must be replaced. The metal fastening clip (999 507 479 02) will remain in use at this point of application.
If necessary, stick a 20 x 20 strip of black felt over the top side of the fastening clip (Figure 14, arrow a. Otherwise, the pale surface of the fastening clip is visible through the cover when installed.
Cover the bottom of the fastening clip with tricot tape Cut off projecting ends of the tricot tape at the sides.
Materials:
Where necessary:
5.2 Side interior trim (E - left/right)
Cause:
The side interior trim (E) or the fastening elements rub against each other and/ or the hardtop.
Repair:
Unclip the side interior trim (E) from rear to front. Pull the rear interior trim toward the middle of the hardtop and withdraw it rearward from the front-most locking point. Check whether the felt strips are present and undamaged (Figure 15, arrows with dimensions). Replace damaged or missing felt strips.
Remove all fastening clips. Completely remove all remaining tricot, felt or other adhesive tape, also from around the openings for the clips on the hardtop.
Fit new plastic fastening clips (999 507 764 40) without tricot tape.
5.3 Rear interior trim (G)
Cause:
The rear interior trim (G Parcel shelf) or the fastening elements rub against each other and against the hardtop itself.
Repair:
Unclip rear interior trim (G). Cut felt Strips approx. 105 x 45 mm, approx. 5.0 mm thick and stick along the rear edge, behind the existing insulation on the inner side of the trim (hatched area, Figure 16, arrows a). Cut off projecting felt.
Completely cut off, grind, or file the contact ribs on the inner side of the lateral cuts, left/right (Figure 16, arrows b) until the surface is smooth.
Remove all fastening clips. Completely remove all remaining tricot, felt or other adhesive tape, also from around the openings for the clips on the hardtop. Fit new plastic fastening clips (999 507 764 40) without tricot tape at the front five fastening points (Figure 16, arrows c) (For fastening at the rear three fastening points, figure 17 shown).
Cause:
Plastic fastening clips touching the hardtop inner panel. If dimensions are out of tolerance, the top (arrow) of the plastic fastening clips may touch the hardtop inner panel when the rear interior trim (G) is mounted.The interior trim therefore does not sit securely and may cause creaking and rattling noises.
Repair:
Before fitting the rear interior trim (G), cut, grind or file the top (arrow) of the plastic fastening clip approx. 0.5 to 1.0 mm.
For each of the three fastening points (Figure 17, arrows d), fit a sheetmetal nut (999 507 030 02) in the previous mounts for the clips (rectangular openings) on the inner side of the interior trim. After placing the interior trim onto these three points, securely fasten the interior trim to the hardtop by screwing in sheetmetal screws (900 143 046 02). Use the washer, P/N: (900 151 027 02) with the screws. Assembly shown below (Figure 18). When screwing in the screws, ensure the trim is centered (even gap width).
5.4 Front interior trim (F)
Cause:
The front interior trim or the fastening elements rub against each other and/or the hardtop.
Repair:
Unclip front interior trim (F). Stick 25 x 30 mm felt strips (Figure 19, arrows) on the six ribs touching the hardtop. Remove all fastening clips. Completely remove all remaining tricot, felt or other adhesive tape, also from around the openings for the clips on the hardtop. Fit new plastic fastening clips (999 507 764 40) without tricot tape.
General:
After carrying out procedures described in 5. (5.1 to 5.4), fit the trim parts again.
Materials:
Internal trim elements material as required.
Complaint 6.1
Rattling from the area of the roof frame seal above the door window (left/right).
Cause:
The screw connections of the retaining rail for the roof frame seal loosen, causing the retaining rail to strike against the roof frame.
Repair:
The lateral roof frame seal above the door window is fixed in the front area by a retaining rail into which this seal is inserted (Figure 20, arrow a). This retaining rail is fastened on the hardtop with four screws (Figure 20, arrows b), which are accessible without detaching the seal. In the rear area, the seal is permanently connected to a second retaining strip (Figure 20, arrow c). This retaining strip is inserted in the previously mentioned retaining rail at its front end. It is additionally fastened on the hardtop with five screws (Figure 20, arrows d).
All nine screws (Figure 20, arrows b + d) are screwed into expanding nuts, which are inserted in the corresponding location holes in the hardtop.
Retighten all fastening screws (Figure 20, arrows b + d).
They can be reached by pushing the outer seal area aside (Figure 21). If the screws cannot be adequately tightened, replace the expanding nuts on the hardtop as described below: Loosen all screws from the rear to the front and remove the seal. Unclip and remove the expanding nuts. which are now accessible. Securely tighten the seal again
(see procedure 6.2. See allocation of the screws and the expanding nuts).
6.2 Rattling from the area of the lateral roof frame seal above the door window (left/right).
Cause:
If dimensions in this area are out of tolerance, the closed door window touches the fifth fastening screw from the front of the retaining strip for the roof frame seal at the top. This causes rattling noises when the vehicle is driven.
Repair:
Push the roof frame seal aside at the fifth fastening screw from the front (Figure 22).
Unscrew previous screw (Figure 22, Item A) and replace with a counter sunk screw (Figure 22, Item B 3.5 x 18 - P/N: 999 450 008 09).
If this measure does not completely eliminate the contact, the door window adjustment must be corrected as described in the 911 Carrera (996) Technical Manual, Group 5, Chapter 57-6, until sufficient clearance is achieved.
Materials:
Allocation of the screws and expanding nuts for procedures 6.1 and 6.2 as shown.
Complaint:
7.1 Squeaking from the area of the roof frame seal above the door window (left/right).
Cause:
Roof frame seal not flocked. The movement between the side window and the hardtop seal when the vehicle is driven will cause this noise.
Repair:
Replace the lateral roof frame seal with a flocked version (implemented in series on 23 August, 99). Procedure according to the 911 Carrera (996) Technical Manual, Group 6 Page 61-81 ff. for removal and Page 61-96 ff. for installation.
Note:
If the trim was removed, all (plastic) fastening clips must be replaced when refitting the trims.
Materials
7.2 Squeaking from the area of the roof frame seal above the door window (left/right).
Cause:
Relative motion between the foot of the seal (Figure 24, Item H), the side of the roof frame and the retaining rail.
Repair:
Undo the five rear fastening screws of the roof frame seal at the side.
Lift the seal and pull it rearward out of the front retaining rail. Disengage seal from the retaining rail. Treat the seal foot with krytox lubricant (Figure 24). Make sure that the interior of the hardtop is not soiled. Press seal into the profile of the retaining rail again and screw it in place at the rear.
Materials
Complaint 8:
Squeaking from the rear area of the hardtop.
Cause:
The rear hardtop seal (I, figure 25) that contacts the convertible compartment lid is not flocked.
Repair:
Pull the seal off the rear of the hardtop and where it pushes into the roof frame seal. Clean the bonding surface of the hardtop with solvent. Insert the new seal first into the roof frame seal at the corners. Then remove the adhesive backing and press the seal firmly onto the hardtop.
Note:
This seal was introduced into production on 16 July '99.
Materials
Complaint 9:
Rattling from the C-pillar area of the hardtop (left/right).
Cause:
The hardtop locking element at rear (Figure 26, Item L) does not engage without play, causing motion between the locking pin on the hardtop and the support on the vehicle when the vehicle is driven.
Repair:
The hardtop locking element is currently being redesigned. An additional Technical Information notice with detailed description will be issued as soon as the final parts that ensure play-free and rattle-free locking become available. No rework solution will be available until then.
Complaint 10:
Rattling from the area of the trim below the rear window on the left and right hand side.
Cause:
The round plastic covers which cover for hardtop latching pin holes on the rear trim panels (D, figure 27) are loose.
Repair:
Check to see if the covers are properly installed. The raised nub in the cover (arrow a, figure 22) is exactly opposite the nub in the trim panel. If necessary, engage it in the correct position. If play still exists, cut a felt strip (10 x 15mm) to size and insert it in the opening of the trim panel where the retaining lug of the cover engages (arrow b, figure 27).
Materials
Complaint 11:
Clicking from the area of the trim below the rear window.
Cause:
The sheet metal panels are riveted together in the interior trim area at the rear of the hardtop (arrow, figure 28). When the hardtop is painted, the paint penetrates between the sheet metal flanges and bonds them together. The flexing of the hardtop causes the paint to break apart at the flanges and that produces loud clicking noises.
Repair:
The paint bond must be broken between the panels. Insert a small slotted screwdriver between the riveted joints of the sheet metal flanges.
Pry them slightly apart until the clicking sound of the paint breaking can not be heard (arrows, figure 29).