Convertible top not coming down all the way

I press the button to lower the top with handbrake engaged. Windows go down Top unlatches It starts to go down Gets almost to the end but the clamshell fails to close all the way - it stops just before it needs to latch onto the rear latch and so I have like a 4 inch gap and I have a convertible top open light. I hear some clicking sounds as it tries to make that last close. The top otherwise operates fast and smooth - so I doubt it's fluid. I can close it fully with no problems. I tried to see if any part of the headliner had come loose, nothing. I tried to see if any cables were binding - nothing. Anyone else had this happen to them and what was the resolution? Car is 996Mk2 so that TSB for the contact switches for the 98/99 MY doesn't apply. Thanks,

Sounds like you may be low on hydraulic fluid. Fill up your reservoir.

Low hydraulic fluid would result in slow or strained/jerky up down movements - as I stated above everything is smooth - the motor just stops engaging towards the end

Did this just start to happen or have you been manually moving the top from the center front manual method. If so you may have to have the top re calibrated at the Porsche dealer.

The clamshell is not driven by the hydraulics. There is a separate motor that rotates a small pinion gear, moving two opposing rack gears (all in a black plastic housing). These in turn push/pull a pair of bowden cables that operate the clamshell and latching mechanism. I'd guess there is an issue with that system, or perhaps one of the microswitches. I've had this system apart multiple times when I had issues with it. It could be a number of things. I think you have to get in there and look around by taking the rear carpet cover off. edit: Here's the thread about the issues I had with the clamshell. You can see some pics of the mechanism I'm referring to at the end of the thread.

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Thanks. - but did you have clamshell closing issues during both the open and close cycle or just the opening cycle like I have ? My clamshell gets stuck only during the final sequence of the open cycle - but perfectly fine during the close cycle...

I actually had no issues until the clamshell hinge broke. I suspect that it was the issue with the clamshell mechanism that caused the entire thing to jam and break. I'm not suggesting you have the exact same problem I had. (my issue was with the rear "slider" that moves the clamshell getting jammed up). I'm only suggesting that your issue has to do with that mechanism in general, and that it's a separate mechanism from the top hydraulics. It could also be a permissive limit switch on another part of the top mechanism that is preventing the "sequence" from continuing. Where exactly is the "clicking" coming from?

You may want to check this guys posting out. Great photos and I think you have the same problem as he had (which he eventually solved) https://rennlist.com/forums/996-foru...more-pics.html Sorry I see that FRISBEE already sent you the same thread.. hope you solve the problem.

Ok thx everyone ! So here's what I discovered - the right side flap doesn't tuck in under the clam shell properly - if I manually tuck it in all is well... https://plus.google.com/photos/11253...CN2jgLi4oY-TDQ Thoughts ?

So I self diagnosed and solved the problem : The flap on the right side was not flipping over quickly enough causing it to not tuck under the clamshell. I cleaned and lubed the guide that is connected to the spring and it's all good now

I got a bit scared after reading this thread and decided to put 'O' ring grease on the hook parts of the clam shell hinge. I also sprayed a little fine lubricant onto the sliders. Also a thin layer of 'O' ring grease onto the plastic hook which goes into the front screen but missed out the tip of the hook which touches the micro switch. Tried it a couple of times and seems to work well and smooth. Not smoother but smooth. Preventative maintenance? not sure lol.

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Nice work! The flaps also have microswitches to ensure they are in the correct position before allowing the next step in the "sequence" (i.e. the closing of the clamshell) to proceed. It's a complex system with lots of things to check on when troubleshooting.