Tech thread: SL broken top release/closing safety lever

[donbryce]

I'm new to the workings of the SL soft top, and as received from the previous owner, the top release lever and safety lever were not secured properly to the serrated post. I had removed them to get the side panel off, and wasn't exactly sure how to reinstall. I somehow put the safety lever on in such a way as to shear both of the little pins off that engage the locking shaft. Uh oh, big bill from the dealer I guess.....

Well, today I bit the bullit and spent a few pleasant hours fabricating a nice repair, one that should last, since the pins are now hardened steel instead of pot metal. Here's the repair story:

Pic 1: Shows the piece from the back side, pins broken off (actually siting there beside it), the bushing I ground up to re-create the pins, and another bushing same size, before grinding. These are common bushings found at motor repair places, I think. The ID is exactly the same as the lever, OD is 5/8".

Pic 2: I drilled out the pot metal lever with a 19/32" bit, just enough under size to allow reaming of the hole to a tight 5/8" press fit for the bushing.

Pic 3: After drilling out the old center section, there is a real thin skirt left on the inner, 'pin' side, and a nice tight hole in the main section of the lever.

Pic 4: I mixed up a small bit of JB Weld, puttied it around the hole, then gently tapped the new piece into it. It was a nice press fit, and the cold weld will ensure it'll never come out.

Pic 5: I made the new piece a bit too long, so had to ream out the plastic washer that goes between the lever and the crank handle, so the handle would fit flush at the end of the pivot post when the retaining cover is on.

That's it. I played around for awhile with the top latching assembly, and still don't really see the purpose of this safety lever. Maybe someone can explain its function? I followed the owner's manual instructions, but they don't go into any detail on this....

[RickM]

Good work.

Pushing the lever down moves the latch that secures the hardtop's rear hold down pin to the release position.

Lever up leaves the latch in the locked position.

[meltedpanda]

Originally Posted by RickM

Good work.

Pushing the lever down moves the latch that secures the hardtop's rear hold down pin to the release position.

Lever up leaves the latch in the locked position.

assuming the cable is in working order, it sometimes self destructs at the connection in the side panel