How to Replace the Roll Pin in a
Boxster
Hardtop Spin-Lock
by topdownride
I was in the process of mounting the hardtop (987-563-
911
-00) on my 2007
Boxster S
for the coming winter, and when I closed the rear catch (aka “spinlock”, “red handled lever”) on the right hand side (RHS) of the hardtop, the roll pin (aka spring pin) in the catch sheared off. (As of now the cause of the failure is unknown.)
The shearing of the roll pin left the large pin on the RHS that holds the hardtop on partially engaged and the catch lever rotating freely (i.e. inoperable). Consequently, the hardtop could not be secured or removed, which meant the car could not be driven without risking damage to the car, hardtop, etc. The price of a replacement catch (L: 987-563-403-01; R: 987-563-404-01) is currently about $150.
Following is how I repaired the hardtop catch to working order for the price of 100 roll pins (approx. $7 + $3 S&H). Presumably repairing the roll pin on a 996/997
Carrera
is similar.
Note, having someone assist throughout the process makes the job much easier.
Tools
- 1/16” punch
- 3/32” punch
- 1/4” punch
- hammer
- 10” (250 mm) adjustable wrench with tapered jaws
- eye loop (magnifying glass)
- flashlight
- feeler gauge
- vice
Supplies
- masking tape
Parts
- roll pin [3 mm (
M3
) x 22 mm, carbon steel, hardened, black anodized]
(also called spring pin, tension pin)
Available from Stock Drive Products / Sterling Instruments (SDP/SI)
https://sdp-si.com/eStore/Direct.asp?GroupID=321
Part # MD1481MQB030X022 ($7.17 per package of 100 pins + S&H, October 15, 2010)
Procedure
1) Disengage the catch locking pin from the securing lock insert.
Use a small (1/16”) hardened punch to insert through the catch lever collar and into the broken roll pin to rotate the catch (987-563-404-01) locking pin sufficiently to disengage it from the lock insert (987-563-714-00) in the car.
2) Remove the hardtop from the car and place in a suitable work area.
3) Cover/protect the catch lever collar in the area around the roll pin with masking tape to avoid scratching.
4) Align holes in catch lever collar with hole through the large securing pin using a medium adjustable with tapered jaws.
Push the jaws of the adjustable wrench between the large cross pin in the securing pin and the small ring washer to compress the wave washer and bring the holes for the roll pin into the same plane. Then rotate the large securing pin to align the holes in the lever collar with the hole through the large securing pin. With the area illuminated with a flashlight, check the alignment using an eye loop.
5) Drive out the broken roll pin.
Use a small (3/32”) punch and hammer to drive the broken roll pin out of the securing pin.
6) Align the collar with the securing pin.
Rotate the securing pin to align the holes in the collar with the hole through the large securing pin. Check the alignment by inserting the shank of a small (7/64”) drill bit through the holes.
7) Prepare the roll pin for easy insertion by slightly collapsing the slot at one end of the roll pin.
Insert a 0.010” feeler gauge into the open slot of the roll pin and use a vice to close the gap onto the feeler gauge at one end of the roll pin over a length of about 2 mm (1/8”). Check that the collapsed end of the roll pin is round, and not oval. Use the vice as necessary to work the collapsed end until round.
8) Insert the slightly collapsed end of the roll pin through the catch collar and into the catch locking pin and drive the roll pin nearly home using a medium (1/4”) punch. To avoid scratching or dinging the collar, use a small (3/32”) punch to drive the roll pin the remaining distance home.
9) Use a small (1/16’) punch to pass through the center of the roll pin from the trailing end to re-open the slot at the leading end.
Work the small punch through the roll pin slowly to ensure it does not become stuck or broken within the roll pin.
10) Test the action of the repaired catch and then proceed to mount the hardtop on the car.
You should add some pictures of this and put it into our Articles section!
Thanks for the encouragement. I know, but I'm still working on finishing a detailed article on "Dual-Use Safety System Installation in a
2007 Cayman S
," which is based around 997 GT2 seats, TC Design harness bar, B-K anti-sub bar, and Schroth 6-
points
. I think folks participating in HPDE will find it useful.
I'm having real trouble getting the roof off to replace the pin. Any suggestions? (
Porsche 987
hardtop)
I have a
986
and can confirm that this process is very similar for the hard top roof removal when the c pin has decided to sheer in the housing. Thank you so much for the simple and layed out walk through!
