An OpenSky is reborn!

The headlining already came off, except those oval clips that hold the sunvisors in place i couldn't take off (attached picture). Any ideas on removing them?
Now, for the job.:) I realize it will be a mother of a job to take apart the OSS down, repair it and put it back on. I do this knowing that everyone recommends the special jig and a complete set of tools.
The jig will be replaced by local means (maybe winches and human power), i have a garage well stocked with tools and the advanced engineering masters i'm attending goes a long way towards understanding the work involved.;) But you do have a point: DO NOT TRY ADVANCED OSS SURGERY UNLESS YOU'RE MECHANICLY INCLINED AND PREPARED TO TURN YOUR CAR INTO A CABRIOLET !!!:p
 
I spoke way too soon. Mine also no longer opens. I does "brrrschk" and that's it. It's closed right now, I don't mind CSS but I'd prefer OSS. I was going to take the headlining out next week anyway, but....

What's the error picture for you guys? It won't move, it won't open, it won't shut or something else?

Bret
 
Just hit the first problem: in the german repair document, the repair piece has the code 8Z0 877 738B, and i've also found another code 8Z0 898 738 B. The first part number is for the piece of plastic that the cables attach to and the second one for the engine gears, any ideas?
 
the doc is ONLY for the repair of the cables. There's some other part numbers flying around a very long thread on the German forums:
8Z0 898 738 - 1 Führung - 1 - 125,08
8D0 877 721 - 3 Schraube - 1 - 5,10
8Z0 898 738 A - 1 Rep. Satz - 1 - 73,40
8Z0 898 738 C - 1 Rep. Satz - 1 - 19,95
G 052 150 A2 - 1 Lith. Fett - 1 - 20,90
8Z0 898 738 - 1 Führung - 1 - 125,08

Apparently, this G052 150A2 is the grease to use on the cables, I will be going to my local dealer later today and will try and bag some of that...

The link, if you're interested, is here: http://www.a2-freun.de/forum/showthread.php?t=23563

Bret
 
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I've already bookmarked the A2-freun post, but babelfish is yet again a mess when it comes to translating.:D
Any english translation for the parts mentioned above?
All i got is "guidance", "screw", "fat" (the grease you mentioned). "rep.satz" i couldn't translate.
Hmm, for so many parts available, it's a wonder why Audi only offer the solution to change the whole roof?;)
 
I don't know. There appears to be a dealer in Bad Tölz who've specialised in fixing these, prices around €440.


let's do some technical German:
- "Führung" translates directly to "leadership". From that --> leader, a slot for guidance, this kind of thing. In this case "rails" is probably pretty good. The recent posts from bag show the profile of the rails (if you haven't registered yet, do so as the pics tell a great tale)
- "Rep. Satz" - "Repair set"
- Fett - Grease, fat. The one in this case is lithium grease.

some more parts for you:

Führung mit Seilzug Nr. 8Z0 898 738 für NUR 127,50 Euro (rails + cables)

Reparatursatz Führung hinten Nr. 8Z0898 738 A für NUR 22,95 Euro (repair set rear rails)

Schiebedachmotor Nr. 8Z0 959 591 für NUR 248,00 Euro (the motor itself)

I will ask someone to go through the thread and summarise it as it's kind of annoying it's got that long (even I have 10+ pages and I have LOTS of posts per page) and there's no summary anywhere.

Bret
 
It's important when attempting a repair to be certain of the fault you're dealing with. Today i scouted the OSS and found that only the closing part of the system is defective, meaning that it opens just fine (when i pressed the button and it started to open normally, i thought i was blessed :eek:) but then i tried to close it and no deal. So now my attention shifts to the cables. I think one of them snapped.
It's tricky to diagnose the assembly without being able to take it apart... I might be forced to take the whole ting down, see what's the problem, order the defective part and keep the car in the garage until the part arrives in order to replace it.
The good news is that it seems almost all the parts that break have an ordering number and can be replaced.
Dunno when i'll be able to get to work, but i promised myself i'll fix the OSS till the autumn arrives.:D
 
Today i went to see if the local parts dealer could order me the required parts if i remove the OSS ans see what's broken. They said it was no problem, and quoted me the following prices, although they weren't able to tell me exactly the code for what's what, so i provided my own codes:
8Z0 898 738 (1 set guides with cable) - 211 Euro
8Z0 898 738 A (repair set guide rear) - 116 Euro
8Z0 898 738 B (repair set guide plate front) - 55 Euro
I couldn't find any set to include only the cables, so i'll risk it and buy the first one. Hopefully it will be the right one.
Now all that's left is to buy a set of extra torx screwdrivers, a beer keg and get to work dismantling the frame.:)
 
What is the latest on the repair to the Open-sky? I recently had mine fail after I thought I had chosen very carefully. I was charged £178 by an Audi dealer just to have my roof closed after it stuck open. They haven't even closed it properly. It whistles at speed as one side slightly sticks up in the airstream. They have disabled it so it can't be used. I would really like to get the roof working again. I really don't think that Audi should get away with selling a vehicle with such an inherant problem.
 
Jesus, 178 pounds for closing your roof... that's full faced robbery.:mad: No wonder the stealers get such a bad rep.
Here's what you do in order to get rid of the hissing sound: have a mate to help you push down the front part of the OSS. Get a "V" shaped sharp tool (i used a camping multifunction swiss knife that had such a head on one of it's blades), search for that metal rail attached to the glass part of the OSS and push it in order to bite the plastic tooth attached to the underside of the assembly. I'm talking about that part of the rail that moved last when the panes were completely closed in order to securely hold them in pace. Will come up with pictures tomorrow because i'm having a garage day for some Touran oil/filters tlc.

Regarding the repair, i'm currently between jobs (aka unemployed:( ) and will have to hold back for a while on the 200E replacement part. But none the less, i'm still pretty bent on repairing it.
The most important thing that you can do is try to figure out what could have gone wrong and see what parts you might need to replace.
And here's a tip for all you fully-insured defective-OSS owners: check if you have declared your OSS on your insurance, and maybe have a trip to some rockfall prone areas.:D
 
Sun visor

Hi Trex,

My poor english didn't allow me to understand if you found a way to dismantle the part bellow.
Please can you give us the solution if you have it ?

attachment.php



Many thanks
 
bretti_kivi said:
the plastic cover is clipped. There are two torx screws underneath it.

Bret
Click to expand...

Ok thanks bretti_kivi.
So , if I understand, i just have to "unclip" the plastic cover with "flat" screw driver (or a small knife) and then the screws are a simple story. yes ?
 
checked an confirmed

Hi bretti

I can confirm the the part in question is clipped as you told.
I used a flat screw driver from behind it (supposing you are on a seat) in order to hide any eventual scratch...

Now, about my open sky, I just discovered than the motor was not the one to blame. It seems to be fully functionnal. I have now two open sky motors :eek: as I just bought one (from ebay.co.uk) thinking that mine was the origin of the issue.

I can't understand what's going wrong whit my opensky.
The symptoms are :
- 2 or 3 cracking noises on the beginning of the opening. The same on the ending of the closing.
- The second panel does not move anymore.

What do you think it is ?
Has some the same symptoms and found an affordable solution ?

Thanks
 
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Open Sky leak

I have just signed in to the forums after 5 yrs lol :) Hello all...
I have recently had a leak in the open sky. After very heavy rain the back seats got soaked and the boot compartment is all waterlogged. There is a pool in the area where battery and tools are stored. Audi want £100 just to look at problem not fix. I have been looking at this myself and found the leak is near the handle on the headliner passenger side rear.
The sky system opens and closes fine sometimes i do get the clunk when the 2nd glass piece lifts. I was told in the past that it needs to be kept lubricated and now its ok.
This leak however is proving to be a pain, Its coming from one side of the cars roof on the far back glass panel.
I am planning on looking at it tomorrow. Any advice manuals would be appreciated. I think it may just be a case the rubber seal has shifted slightly.
I was told it could be drains clogged up but don't know where these are. I have found black panels where the boot opens and found these had a lot of black grime in them cleared that out so will see what happens tomorrow...
 
It looks like the issue is fixed thanks a lot for that link Bret turned out the drain seals were blocked.
I ran a wire coat hanger under the seal and that seems to have cleared it...
 
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