Auto Free Top stuck closed after removing motors ,Handbook

[paulsilsby]

I hope someone can help, the other day my son managed to get me a flat battery whilst the roof was up.
So that I could leave my Bongo in safety to get the battery recharged I performed the closing technique
as per the hand book.
The roof is now closed with the motors detached and I have fitted the recharged battery, but the roof is
jammed solidly shut. I have tried pushing it hard from inside through the hatch and pulling the rope towards
the rear of the camper in an effort to get it to come back up.
Is there some sort of mechanism locking it closed ? Unfortunatly the Handbook has no information on opening
the roof again.

Many thanks
Paul Silsby

[paulsilsby]

By appying a serious amount of force pulling back on the rope there was a clunk and one side or the roof has now lifted about 4 inches. The other side is stuck firm no matter how hard I try , I even tied the rope to a tree and let the Bongo creep forward on Automatic untill the rope stopped it.
I cant find anything that says that says that the roof locks closed anywhere out there, so what could be holding it down. Has anyone got a good photo or drawing of the Mechanism for the roof , prefererably when it is nearly closed. Then at least I could detremine whwre and if I need to cut a hole in the side of the fiberglass roof to gain access to the Mech ?

Any suggestions appreciated.

Many thanks
Paul

[mikeonb4c]

Whereabouts are you based. Don't cut a hole in the roof if you can possibly avoid it. Adrian at Japan Direct in Bury (0271-763-3003 from memory) has sorted mine before when it was stuck down. He's very helpful and familiar with aft roofs. Tell him Mike said to call. Good luck, keep us posted

[g8dhe]

There isn't a lock as such, but there is a covered area, which is a little lower, the cover stops the trolley from lifting upwards. However when you try to pull the trolley back with the rope, you really need to lift the rear end of the trolley out of the dip as well, this I suspect is where the problem is, you need to try to lift the back of the trolley at the same time as pulling it towards the rear! Merely lifting the roof doesn't work as its lifts the front as well as the rear...

[paulsilsby]

Thankyou both for your replies.

I live on the south coast near Brighton. I'm not shure where Bury is but I will give him a call anyway.

Meanwhile this thing about the trolley seems to make sense. I will have to think if there is some way
to get it to lift out of the dip. If only I could turn my Bongo upside down , I think that would sort it.
Maybe I could make up a special tool that slides under the lip of the roof and then flips the trolley out of the
dip. Any idea how far back from the front of the AFT I might need to do that ?

once again thank's
I really appreciate both of your comments

Paul

[g8dhe]

Paul, I'll try to get out and takes some photo's today provided the rain stays off, along with some measurements, that should lets see what sort of tool is required. It may be sufficient just to push a flat strip up under the roof, provided it will go in at sufficient angle to engage with the rear of the trolley or maybe a tool to hold the cord horizontal whilst pulling towards the rear at present I suspect the cord is pulling downwards as it has to come down under the roof seal.

[MountainGoat]

Bury is just outside Manchester, a bit far for you. Perhaps Discount Trucks near Newbury in Berkshire could help you if you are unable to follow the above advice.

Tony

[Dr Fingers]

Phone County Cars, Portslade, speak to Colin.

01273 422511

Derek

[g8dhe]

Right just been out before the snow got any heavier!
Pictures of the setup here http://www.g8dhe.net/pictures/2013/04/20130403/ Select a thumbnail and click and click the larger image for a fullscale image, a third click will expand to ultimate size!
I am thinking that the two bolts holding the plastic cover in place, it might be possible to loosen from inside the cab by removing the headlining, but its not clear from the diagram below if the bolts do pass right thru or if they are held in place above the roof ?
http://lushprojects.com/bongopartsmk2/c ... 2of02.html

Measuring from the front tip of the roof it is 34 inches to beyond the plastic trap and 38 inches to the point where the aluminium rail top section is trimmed down to allow the trolley wheels to lower into the plastic trap.

[paulsilsby]

Wow.. Thank's Geoff

You are indeed a supreme being.

I will see if I can get out and take a look at it later on Today.
Yes as you say the rope (well actually baggage straps as they lie flat and don't damage the neoprene seal) is pulled straight
along the gutter to a tree, but of course it then goes up at an angle under the roof. Still I will have a try to do it myself and
if so I will let you know. Otherwise it looks like if all else fails I will have to contact Colin at County Cars as suggested.

Thank's Guys

Paul

[Ian]

You might find this thread useful, especially splitpin's manual solution:

http://www.igmaynard.co.uk/bongo/forum/ ... oof+blocks

[g8dhe]

Ah good find there Ian I'll stick that on the Bookmark list!
Its always slightly concerned me that if it ever got stuck, it was going to be a bugger to raise again, but that confirms the need to push the trolley upwards with the screwdriver, I think a torch would also be helpful to locate the right position!

[paulsilsby]

Hi Guys

Unfortunatly one side is down so tight that nothing will go under the roof, certainly not a screwdriver.
The trolley most be located firmly in the plastic cup which looks as it's designed for the purpose of holing down the roof.
I guess it wont pull back as it catches in the aluminium rail when pulling back and down a bit, whereas if the motor was
connected it would pull back and up a bit.
Now I rang County Cars by Colin was not there , so I spoke to his son who advised that I would have to force the roof up from the inside
using a jack in necessary. I will not try this as I think he is mistaken and it will just break either the raising mech or the plastic cup.
Hopefully when I get hold of Colin he will have a better idea.
Meanwhile I am begining to think that with the benefit of your photos I can work out where to drill a small hole in the fiberglass just to the side of the trolley so that I can get a screwdriver in. Afterwards I just need a rubber grommet of the correct size to fill the hole. This will also be re-usable in the future and could be a good idea for all Bongo users. Assuming it works OK ?

Best regards
Paul

[paulsilsby]

Just read my last Post and I can't believe how bad my typing is...
Cheers
Paul

[mikeonb4c]

Hi Guys

Unfortunatly one side is down so tight that nothing will go under the roof, certainly not a screwdriver.
The trolley most be located firmly in the plastic cup which looks as it's designed for the purpose of holing down the roof.
I guess it wont pull back as it catches in the aluminium rail when pulling back and down a bit, whereas if the motor was
connected it would pull back and up a bit.
Now I rang County Cars by Colin was not there , so I spoke to his son who advised that I would have to force the roof up from the inside
using a jack in necessary. I will not try this as I think he is mistaken and it will just break either the raising mech or the plastic cup.
Hopefully when I get hold of Colin he will have a better idea.
Meanwhile I am begining to think that with the benefit of your photos I can work out where to drill a small hole in the fiberglass just to the side of the trolley so that I can get a screwdriver in. Afterwards I just need a rubber grommet of the correct size to fill the hole. This will also be re-usable in the future and could be a good idea for all Bongo users. Assuming it works OK ?

Best regards
Paul

He's definitely wrong. Call Adrian. I think he says the only way is by undoing bolts accessible from inside the rear of the Bongo (look for grommets in the headlining). He is then able to manouevre the roof so it can be cracked open. But you need a hoist facility as its way too heavy to do manually.