AFT Roof wont raise or close.

[THEMUTSNUTS]

Hello all bongoerits,
Howie im not sure when this thread started but if you are still on here and still have instructions please pleas can i get a copy.
Praying you get this lol
Chris

Right guys I've had enough of messing around with the electric roof.......!!!

I've now removed the roof motors and the AFT roof struts so the roof is now totaly manual like a VW. The gas struts help when raising the roof but they're not strong enough to hold it open so I've now cut a ally pole to length which props the roof up. I now know I'm never going to be stuck with the roof in the up possition. The roof when traveling is held dow with rubber ball and socket straps.
The only problem I have is...... the roof alarm will not shut up.....!!!!
Does enyone know how to shut it up without getting to the sounder? My kitchen is in the way so I can't get to the off side wheel arch.

If anyone wants a "how to do" on converting the roof to manual I'll put a fact sheet together.

I know some of you will think I've done wrong but I needed to be sure I can come and go as I please, not when the Bongo wants to.

Howie

[g8dhe]

Welcome aboard!
Raising
Make sure that;
The engine is running.
The handbrake is on and the brake light on the dash is lit ??
If the brake light isn't coming on, then check the little switch at the back of the handbrake (remove console) on passenger side they get dusty and dirty.
Now press Up the bleeping should start ??
If not then check the fuses (not likely but easy to do).
If they are OK and its bleeping, then check the rubber seal isn't stuck to the roof with age, run a card around to release it.
If that is OK then operate the Up then Down switch LOTS of times, it might be a dirty switch contacts or it could be corroded motors, by turning the motors even a little bit it might free up the corrosion and let you get the roof up. If so then drop out the motors at the rear and check for corrosion, there is a good Fact sheet if your a member of BongoFury on the process. Otherwise if the roof won't go up still then the is a method of lifting it but its not easy!
http://www.g8dhe.net/bwm/default.htm

Lowering
Make sure that;
The engine is running,
The handbrake is on and the brake light on the dash is lit ??
Press the Un-lock button in the AFT. Beeping starts.
Now press Down button.
It will stop half-way for a final visual inspection,
Press Down again.
If not then check the fuses see below,
If the brake light isn't coming on, then check the little switch at the back of the handbrake (remove console) on passenger side they get dusty and dirty.
If it still won't budge then refer to the User Handbook for the vehicle, which has a Manual method of lowering it, requires Allen Key and thin rope.
https://www.amazon.co.uk/Mazda-Bongo-Fr ... 869761561/
http://www.g8dhe.net/bwm/default.htm

[Wpserle]

I know this is super old, but hoping someone can help!

Have got roof up after removing 10mm bolts (6 each side one hidden up a recess which I missed! )

Just looking for a bit a clarity on the get at the motors and reset everything bit please!

Both motors work, but just clunck when switched forwards to backed like something is jammed.

Thanks!

Will

Mine has one weak motor and another very weak one, if I try to raise it it goes a little eay and quits, but after resetting (disconecing the battery and wait a bit) I can persuade it to open by pushing to assist the motos, I have to stop pressing the button if I want to stop pushing or the whole thing jams in place.

If yours has quit completly, then the easiest way without getting yourself into a potentail fix as I did - remove the headlining both main and cab area - you will need to unscrew all the grab handles etc to remove the upper plastic trim to get the headlining off.

Then undoo all the 10mm bolts along both sides - don't undo the larger (14mm?) these are the Strut and hinge bolts, you want to leave these in place.

Now you can manually push the roof up, yes the two rails will flop about but you can get at the motors and reset everthing.

I made the mistake of undooing the rear hinges, but the struts of course just tried to pull the roof forward, it was stopped by the roof tent, I had to secure the roof bars to a beam in my garage and drag the whole assembly back into position to get the roof back in place - lesson learned the struts can be powerfull.

[g8dhe]

Not quite sure what you mean? Have you removed the entire roof or just the two motors? It sounds like you have removed the entire roof?

Once you have the motors off then they will need cleaning inside normally, have you read the Factsheet on cleaning them in the Members area? https://igmaynard.co.uk/wp-content/uplo ... ervice.pdf this shows how to go about opening them up and cleaning, be aware of the single ball bearing at the very bottom of the motor tube, it will either drop out and run away or stick to the magnets!!

[Wpserle]

Following Idris process I've stripped headliner and have undone the 10mm bolts from inside for the rails.

Roof now lifts manually, is still attached via rear hinges and gas struts.

Idris mentioned you then "reset everything", I'm just wondering what that might mean in terms of physically what I need to do.

I'd previously had the motors off and knowing they are good.

Thanks for any help you can provide.

Will

[g8dhe]

He means as he says in the write-up disconnected the Starter Battery and allowed the electronics to reset. However that won't fix a motor problem, it might fix a fault in the control module electronics, but the most common problems are simply dirty switches, either the Handbrake switch or the Up/Down three way toggle, both get very dusty and dirty.
If the Handbrake switch is the problem then you won't have a Handbrake light lit on the dashboard - remove the console cover and clean the switch out from the passenger side - its a very crude switch gets carpet fibres stuck in it!
If the handbrake light works then next most frequent problem is the Up/Down switch in the cabin roof, pop it out and clean the contacts;
See https://www.youtube.com/watch?v=tX1SB0xoJOU

Make sure that;
The engine is running.
The handbrake is on and the brake light on the dash is lit ??
If the brake light isn't coming on, then check the little switch at the back of the handbrake (remove console) on passenger side they get dusty and dirty.

Now press Up the bleeping should start ??
If not then check the fuses (not likely but easy to do) http://www.g8dhe.net/bwm/ .
Else if not clean the switch https://www.youtube.com/watch?v=tX1SB0xoJOU

If they are OK and its bleeping, then check the rubber seal isn't stuck to the roof with age, run a card around to release it.
If that is OK then operate the Up then Down switch LOTS of times, it might be a dirty switch contacts or it could be corroded motors, by turning the motors even a little bit it might free up the corrosion and let you get the roof up. If so then drop out the motors at the rear and check for corrosion, there is a good Fact sheet if your a member of BongoFury on the process. Otherwise if the roof won't go up still then the is a method of lifting it but its not easy!

What ever you do please don't push on the roof itself, until the sliders are out of the locking shrouds, otherwise you stand a good chance of damaging the seal around the skylight, if the gas struts are tired and need replacing then a little assistance for the last few inches is acceptable.

Finally mechanical things NEED to be used, it causes the oil grease to spread out rather than pool and helps to reduce corrosion. Don't leave things unused for months on end....

Finally if nothing works then https://www.youtube.com/watch?v=PaSzghJ2tE0

[Wpserle]

Thanks for clarifying and the detailed reply.

For completeness

I have done all the normal "basic checks"
Fuse handbrake etc.

One motor wasn't working have replaced, as per video you shared, it was a massive faff!

Controller seems fine providing helpful beeps!

With roof raised (manually after unbolting rails from inside) and with motors out but still connected electrically, they both drive as expected on the roof switch.

The motors just don't seem to be driving the rasing mechanism which I've greased and given som gentle encouragement with a hammer, so think they are able to slide.

When motors are attached I can hear them clunking and see the end of the rasing mechanism move a tiny bit each way, just not being driven properly.

So I guess there is something mechanical stopping the motors from turning the worm drives?

Very frustrating perhaps I'll go manual roof with designer ratchet strap!

Thanks again!

[g8dhe]

Your aware the that the two Teleflex cables run down from the front/top of the roof (pulling/pushing the mechanism) thru the motor gears and then cross over around the back and go back up the other side again via the gears however they are free on the opposite side, this ensures that both sides of the roof stay in sync as it goes up and down. Some layout details here;
https://www.lushprojects.com/bongoparts ... 2of02.html

[Wpserle]

Was not no thank you, I'm not going to pretend to fully understand this but the behaviour I see;

With the motors out the mechanism moves freely, I noticed only one side of the "gear bars" ( teleflex?) where the motor cog connects moves when I move the mechanism by hand , this the same both sides.

Is that as expected, from what your saying Geoff, perhaps they are the synch part of the system so not expected to move freely?

Thanks again!

Your aware the that the two Teleflex cables run down from the front/top of the roof (pulling/pushing the mechanism) thru the motor gears and then cross over around the back and go back up the other side again via the gears however they are free on the opposite side, this ensures that both sides of the roof stay in sync as it goes up and down. Some layout details here;
https://www.lushprojects.com/bongoparts ... 2of02.html

[g8dhe]

Here are a series of images about the roof in general, from this point on are images about the Teleflex cables and how there driven by the motors, as you can see both Teleflex cables are driven on both sides by opposite sides of the crown pully driven by the motors. http://www.g8dhe.net/bongo_images/aft/index.php?ind=15

[Wpserle]

I'm sure you're bored of me by now...

However if I only connect one motor the mechanism (both sides) drive and moves
Roof is open, so it's not working to lift / lower as I've disconnected the mechanism rom the rails.

Beeping stops when fully open , roof lock operates as expected n'all.

So I guess something between the two motors is going wrong.

Can they get out of synch?

Or is the polarity maybe wrong and they are driving against each other... Will continue to muck about!

Cheers,

Will

[g8dhe]

Not sure that is a wise move! Its absolutely critical that both sides are kept in step otherwise you cause the roof to twist and snap, one motor is not normally of sufficient power to lift the entire roof. There have been MANY examples where one motor has come loose and then the roof twists and fails in very short order - i.e. two or three seconds after power is applied!! There are several reports on the board of exactly this happening, once a motor has dropped away a little then the bezel crown gear is not driving both cables with fatal results.

The motors are kept in sync by the bezel crown gear and both cables going thru them on each side. The motors themselves are identical and powered in parallel but are not synced electrically in that sense.

[Wpserle]

Update, I'm a total idiot, when I was testing the motors I must have reversed wires on one when putting it back in the connector

OMG, that's a massive life lesson!

Will now rebuild all the bits I have unnecessarily taken apart... and hope it all works!

[g8dhe]

Oh one other thing, don't be tempted to oil or lubricate either the channels that the lifting mechanism runs in or the gas struts!
The mechanism has small plastic wheels that run in the channels, if there lubricated dust and dirt sticks to the oil and causes them to skid and jerk around - just as you don't oil beneath your tyres on the road!!
The gas struts are sealed to a very high degree, clean the lower silver sections with a clean dry cloth only, again do not lubricate as it causes dust to be forced into the seals destroying them, if the roof lifting slows down or doesn't reach the top to turn off the beeping then its time to replace the gas struts SGS do replacements ones, do note that there are two types earlier models the roofs don't go as high hence a shorter strut, later models need the slightly longer struts. All the struts are listed here https://www.sgs-engineering.com/car-boo ... azda/bongo