'04 CLK500 - Convertible Roof Malfunction - Help!?

57528 Views 84 Replies 14 Participants Last post by rudeney, Mar 23, 2019

Adrian's1stBenz

Discussion Starter · Sep 27, 2011

Hi...

My roof has now started to malfunction :surrender:

Putting Top Down:
When I put the top down, it goes all the way down, and then when the "cover" is trying to lock in place it jams (see picture).

If someone holds the button while putting the top down and someone else pushs down on the "cover", it will lock in place like normal.

Putting Top Up
Then when I bring the top back up, it goes all the way, and then when the "cover" is trying to lock back in place it jams again.

If I lift up and down on the button a couple of times, when putting the roof up, the "cover" will make a loud thud noise and lock back in place like normal.

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21 - 40 of 85 Posts

rudeney

· #21 · Sep 1, 2012

George, check the hinges on the cover. There is a locking mechanism made of plastic that helps support the cover in the full-open position even if hydraulic pressure is lost (it's a safety feature for when working in the compartment with the cover open). Sometime the plastic arm breaks and can make it difficult for the cover to close, and may even make a loud "pop" noise as it closes (to chrisos1's comments). If the plastic arm is broken, you can just go ahead and break it off completely to remove it - again, it's just a safety when servicing with the cover open. If it's not that, then I think you have a bad hydraulic cylinder.

clk55amguk

· #22 · Apr 27, 2013

Hi, I would like to know if this was resolved. I have an identical issue I think (assuming we are talking about the same then when we mean the roof is opening and closing)

After a long time without opening the roof following the traditional 11 month uk rainy season I finally got he chance to open the roof last week. When opening the roof (i.e. going topless) there was a clunk as the very last stage of opening completed. Where the cover goes flush with the rest of the body. Similarly when opening the final part of the operation where the metal cover goes flush it seems to stall there until the glass part comes back down 'smacks' it closed. I read up and decdied I needed to grease some catches etc.

Unfortunately today the problem is worse. In the OP's pic when opening the roof the cover is stuck. I can hear the system still pumping, it just never makes it to be fully closed.

Opening is still as last week. It hangs open until the glass portion smacks down and fully closes it with a clunk.

It could be hydraulic or mechanical, not sure which. Of course I might just need to grease the correct part. Here's hoping.

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rudeney

· #23 · Apr 27, 2013

It's probably a bad hinge on the cover. The two hinges have a plastic cam that allows them to lock the cover safely in the open position for servicing. First of all, open the trunk (top open or closed) and remove the plastic covers snap onto the cover hinges. Then look to see if you have a broken plastic arm hanging in the middle of the hinge. If so, this is the problem. There are two plastic "ears" sticking out of the side of the hinges, Pull outward on them, and then rotate them both forward (this is the same procedure outlined in the owner's manual for emergency closing).

Once you do this, the cams will no longer be engaged to support the cover, so it will rely solely on the hydraulics. That's fine unless you are going to service the hydraulics with the cover open (and then it would slam shut!). If you do have a broken plastic arm, you should break it away completely or at least pry it so it rests flat on in the water channel and is not hung inside the hinge.

The hinges are easy to replace - just a few TORX bolts, and cost about US$150.

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gebe1

· #24 · Apr 27, 2013

Thankyou for the reply. You were correct, the plastic cam was broken. I did replace it, however, it's not straightforward. Getting access to the third torx bolt is very difficult. Also, in Australia the plastic cam costs almost 3 times as much !! Anyway, seems to have fixed the problem, now I'm wandering why it happened, and hoping it won't again.

rudeney

· #25 · Apr 28, 2013

Oh yeah, I forgot - to more easily remove and install the third bolt, do it with the cover open. And yeah, I know parts are less here in the USA. In my case, both of mine are broken and I have not replaced the hinges. If I do have a need to work with the cover open, I'll just use a prop.

clk55amguk

· #26 · Apr 28, 2013

Ah that's exactly the problem. I didn't have a plastic cover over mine so it threw me a bit.

For everyone else this is the best picture showing what is going wrong. You will probably be viewing it from the other direction though...

Thanks

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rudeney

· #27 · Apr 28, 2013

Yep - either totally break off those plastic pieces, or move them so they don't interfere with the hinge. Like I said, this is only used to support the cover when you work on the hydraulics, so it has nothing to do with normal operation.

Adrian's1stBenz

Discussion Starter · #28 · Apr 29, 2013

clk55amguk said:
Ah that's exactly the problem. I didn't have a plastic cover over mine so it threw me a bit.

For everyone else this is the best picture showing what is going wrong. You will probably be viewing it from the other direction though...

Thanks

Unfortunately, I've put off taking it in to get checked out. Stupid me, I did the dumb dumb thing and pushed (forced) it closed, and now the roof is closed and will not even disengage when attempting to open it, though you can hear the "roof motor" running, nothing happens.

rudeney

· #29 · Apr 29, 2013

Adrian, what part did you force? The windshield latch? The glass mating to the rear cover? Or the rear cover itself?

Adrian's1stBenz

Discussion Starter · #30 · Apr 30, 2013

Hatch was broke, then attempted to close the roof, it closed automatically and latched onto the windshield like usual, I then forced the rear cover to close in place. Now, when attempting to open the roof, the rear cover doesn't budge but the motor is running.

rudeney

· #31 · Apr 30, 2013

If you open the trunk, can you see these hinges? Do they appear to be broken like the photo? Or, maybe by forcing the cover closed, you damaged a hydraulic cylinder. Does the pump have fluid in it? You might try doing a "manual open" (basically do everything for manual close, but fold the top into the trunk instead of pull it out). Bu before doing that, with the cover open and the top still closed, check the struts and hinges for damage.

Adrian's1stBenz

Discussion Starter · #32 · Apr 30, 2013

rudeney said:
If you open the trunk, can you see these hinges? Do they appear to be broken like the photo? Or, maybe by forcing the cover closed, you damaged a hydraulic cylinder. Does the pump have fluid in it? You might try doing a "manual open" (basically do everything for manual close, but fold the top into the trunk instead of pull it out). Bu before doing that, with the cover open and the top still closed, check the struts and hinges for damage.

The photo is a pic of my actual car. 1 hinge (drivers side) is busted for sure. I will try the reverse manual roof open procedure and look for further damage tomorrow. Will post what I find.

clk55amguk

· #33 · May 1, 2013 (Edited)

Hi, I trimmed back the broken arm and it seems better. I also notice one of the metal 'clip springs' is off. Is this part safe to discard or do I need to fix this?

Also do I need to remove just the plastic arm or the whole central plastic part with a mini spring on it?

Thanks

rudeney

· #34 · May 2, 2013

You can safely remove all of the plastic and the metal clip. All you need for operation is the hinge itself. That plastic and the spring metal part is just to lock the top open without hydraulic pressure.

MikeDC

· #35 · May 2, 2013

Adrian's1stBenz said:
Hi...

My roof has now started to malfunction :surrender:

Putting Top Down:
When I put the top down, it goes all the way down, and then when the "cover" is trying to lock in place it jams (see picture).

If someone holds the button while putting the top down and someone else pushs down on the "cover", it will lock in place like normal.

Putting Top Up
Then when I bring the top back up, it goes all the way, and then when the "cover" is trying to lock back in place it jams again.

If I lift up and down on the button a couple of times, when putting the roof up, the "cover" will make a loud thud noise and lock back in place like normal.

The cover on my car is stuck straight up. I haven't been able to check if the hinges have the broken "safety" locks because I'm waiting for a tow truck. So here's my question, can this car be towed with the cover sticking straight up, or is the wind gonna blow the cover over, or bend it, etc.?

rudeney

· #36 · May 2, 2013

I wouldn't go more than 30-35mph with it like that. There is a process for manual closing outlined in the owner's manual. I have the shop video here (it's an E-class A207, but it's identical otherwise):

benzbits.com/W209/Soft_top/ManualClose.wmv

Another possibility is that you could disconnect the hydraulic struts where they mount to the cover - they have small metal clips that have to be pried slightly with a screwdriver, then they unsnap from the cover.

MikeDC

· #37 · May 2, 2013

rudeney said:
I wouldn't go more than 30-35mph with it like that. There is a process for manual closing outlined in the owner's manual. I have the shop video here (it's an E-class A207, but it's identical otherwise):

benzbits.com/W209/Soft_top/ManualClose.wmv

Another possibility is that you could disconnect the hydraulic struts where they mount to the cover - they have small metal clips that have to be pried slightly with a screwdriver, then they unsnap from the cover.

Thanks for the reply. Problem is, with the "lid" stuck open, you can't open the trunk. If I can just get the lid down, I can drive it no problem. The roof is fully open and stowed. I'm hoping the plastic safety pieces on the hinges are broken and that is what is keeping the roof open.

rudeney

· #38 · May 2, 2013

OK, in that case, just unclip the hydraulic struts from the cover and then you should be able to close it. This should explain it:

http://www.benzworld.org/forums/w20...problem-can-not-open-close-2.html#post5616833

MikeDC

· #39 · May 2, 2013

rudeney said:
OK, in that case, just unclip the hydraulic struts from the cover and then you should be able to close it. This should explain it:

http://www.benzworld.org/forums/w20...problem-can-not-open-close-2.html#post5616833

Thanks!! I can easily unclip the hydraulic struts, however, I cannot move them completely out of the way in order to lower the lid. Again, have to get into the trunk to release the hydraulics. But now I know IF I could release the hydraulics, I could get the lid down and then safely drive the car. (BTW, the tow truck driver would not tow it in this condition.)

Adrian's1stBenz

Discussion Starter · #40 · May 2, 2013

Dropped it off at a trusty Indy today... just too many possible issues, would take me forever to try and figure it out. Stay tuned.

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