Removing part of a conversion

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Paltibine
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Removing part of a conversion

Post by Paltibine » Sat Jul 06, 2019 4:30 pm

Wasn't sure if this should go here or in the conversions forum but here goes:

My AFT roof won't go up with the roof light coming on, bleeping and dash lights dimming but no roof movement. So the next thing to look at is the control unit in the rear but on a converted Bongo that means removing part of the conversion. In my case it's the block with the fridge and the Zig unit. I've got no real idea how this part is held in which is what I'm looking for some suggestions with....

The conversion is one of Madmiles (for those of you who remember) and I may need to get in touch with him but I thought I'd ask for ideas here first.

I am working on the assumption that I can remove the "fridge block" as it was built in a modular way rather than constructed around the fridge, is that likely? I have found and removed several screws from the lower cupboard into the base of the fridge unit and several between the overhead lockers and the fridge unit. The unit is now "loose" in that it moves a few mm mainly by rotation. It may be held in by the wiring but without moving it a bit more there isn't any way I can see to get behind it to detach them?
Any idea where I go next with this?

I've tried to share some pictures....

https://drive.google.com/file/d/10K4QO_ ... sp=sharing
https://drive.google.com/file/d/10EJkuW ... sp=sharing
https://drive.google.com/file/d/10BxPCA ... sp=sharing

Thanks in advance.....
Bob
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Re: Removing part of a conversion

Post by Bob » Sat Jul 06, 2019 7:13 pm

Before you start stripping things appart let's see. :wink:

The beep is working and the dash lights dim.

Are you running the engine while trying to lift the roof?

The fact the dash lights are dimming suggests the motors are taking power, so could it be the rubber seal is just stuck down? How long since the roof was last up?

Hope these thoughts help. [-o<
Paltibine
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Re: Removing part of a conversion

Post by Paltibine » Sat Jul 06, 2019 9:24 pm

Thanks Bob but yes, running the engine and revving hard. No movement at all but as you say, motors are drawing current I'm sure. The Bongo has been having trouble with several switches and wiring connections over the last 2 years or so and the roof switch stopped working completely a while ago until I removed and cleaned it all up.

Roof was last up in middle of May and was a bit reluctant to close properly. I had to rev the engine significantly to get the beeper to stop. It has needed help to raise fully the last couple of times. I'm hoping it's just dirty contacts on the connectors but have to get it open to see what's going on.

The factsheet is a bit advanced in the sense that it assumes that you know how to remove all the headlining which will be the next job after getting the fridge module out of the way.....
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g8dhe
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Re: Removing part of a conversion

Post by g8dhe » Sun Jul 07, 2019 4:00 pm

That rather sounds like stalled motors, often due to corrosion inside the bodies of them, there is a fact sheet in the members area on how to clean them, read that first.
The problem is gaining access to the motors themselves with the roof down! However the following has worked for a few people, get yourself ready with a comfy stall, to sit on and use the normal procedure to start with, then operate the Up/Down switch between the two positions LOTS of times!! What your trying to do is cause the motors to swivel to and fro and hope that it will dislodge the corrosion inside the motors sufficiently to allow you to lift the roof and gain access and then immediately drop the each motor in turn (prop the roof) and use the Factsheet mentioned above to clean each motor. As I say it has worked fr a few people but does require lots of operations of the switch 100+++++, otherwise your in for a major operation to release the entire roof mechanism and lift it clear of the vehicle in order to get to the motors :-(
Geoff
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Re: Removing part of a conversion

Post by Merlot man » Wed Jul 17, 2019 8:38 am

Hello all
On a related note , is it possible to get reconditioned motors as I've read the fact sheet and it looks a bit fiddly to a wrench monkey Like me :lol:
Mine seem to be working ok but I was thinking of replacing them as a preemptive strike .
Any ideas ? This might help the OP as well .
Thanks in advance
Brian
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g8dhe
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Re: Removing part of a conversion

Post by g8dhe » Wed Jul 17, 2019 9:08 am

Geoff
2001 Aero V6, AFT, full side conversion.
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Re: Removing part of a conversion

Post by Merlot man » Wed Jul 17, 2019 10:17 am

g8dhe wrote: Wed Jul 17, 2019 9:08 am You can buy new ;-) https://mazdabongo.com/product/mazda-bo ... ll-models/
Thanks for the link Geoff , I have found them there before , it's the price that's putting me off :shock:
£210 per side !
Appreciated
Brian
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Re: Removing part of a conversion

Post by Merlot man » Wed Jul 17, 2019 10:40 am

Just checked the bongoland shop and these are £195 - members discount ! It's going the right way ,anyone else have any leads on new or refurbished motors ,it could help a lot on here \:D/
Brian
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mikeonb4c
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Re: Removing part of a conversion

Post by mikeonb4c » Wed Jul 17, 2019 11:16 am

Merlot man wrote: Wed Jul 17, 2019 10:17 am
g8dhe wrote: Wed Jul 17, 2019 9:08 am You can buy new ;-) https://mazdabongo.com/product/mazda-bo ... ll-models/
Thanks for the link Geoff , I have found them there before , it's the price that's putting me off :shock:
£210 per side !
Appreciated
Brian
I bit the bullet and fitted two new motors many years ago. Expensive but no trouble since (touch wood!)
Paltibine
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Re: Removing part of a conversion

Post by Paltibine » Sun Jul 21, 2019 3:40 pm

Sorry for the quiet patch but I've been away. Back to the Bongo again now though!

I've just spent a while switching the roof up / down - probably several hundred times but no sign of any movement at all. :(

So it looks like I'm looking at trying to detach the whole roof from the van and in order to do this, I'm going to have to take out the head lining and to do that I have to remove the top part of the conversion with the fridge. I have already removed all the screws I can see and it moves a bit but there is obviously still something still holding it in place. I really hope it isn't held in from above as that would leave me in a classic Catch 22?

How are these things usually fixed to the vans? Any suggestions or do I have to go back to the converter?

Thanks all....
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Re: Removing part of a conversion

Post by mikeonb4c » Sun Jul 21, 2019 11:02 pm

Paltibine wrote: Sun Jul 21, 2019 3:40 pm Sorry for the quiet patch but I've been away. Back to the Bongo again now though!

I've just spent a while switching the roof up / down - probably several hundred times but no sign of any movement at all. :(

So it looks like I'm looking at trying to detach the whole roof from the van and in order to do this, I'm going to have to take out the head lining and to do that I have to remove the top part of the conversion with the fridge. I have already removed all the screws I can see and it moves a bit but there is obviously still something still holding it in place. I really hope it isn't held in from above as that would leave me in a classic Catch 22?

How are these things usually fixed to the vans? Any suggestions or do I have to go back to the converter?

Thanks all....
Shouldnt need to remove the headlining. But you do need decent hoisting gear i believe. It'd ve worth phoning one of the Bongo specialist garages for advice on best course of action. I use Adrian at Japandirect in Bury and he's fixed countless failed roofs.
Paltibine
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Re: Removing part of a conversion

Post by Paltibine » Wed Jul 24, 2019 9:51 pm

I had assumed that I would need to remove the roof lining in order to get at the bolts that hold the rails to the roof? But first I've got to get that fridge out. Nobody seems to have any suggestions so I guess I'll try and contact Ed over the next week or so. I may also see if he's up for quoting for the whole job while I'm at it!
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Re: Removing part of a conversion

Post by Bob » Wed Jul 24, 2019 10:41 pm

Trouble is all converters have their own methods so it's not likely anyone else will know how it's fitted unless they have taken one out.

Ed is a good chap and I'm sure he will help out. :)
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