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Vario roof not working? Might be your Trunk Flap. Easy Fix DIY

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SL-Class (R230) 2003 -- 2012: Discussion on the SL500, SL550, SL600

Vario roof not working? Might be your Trunk Flap. Easy Fix DIY

 
Old 06-15-2017, 06:32 AM
  #51  
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Apologies for bumping an old thread, but my R230 has this problem, and for some reason I cannot see the tutorial in this thread (second post is blank). I have registered and logged in but still the same, can anyone advise please?
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Old 06-18-2017, 01:42 PM
  #52  
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Repair made without new parts


Hi. Thank you for he original post as it helped immensely, however I found that the adjustment worked fine.


I took the whole flap movement thing apart to check for the defective part, but all looked Ok. The bars that are suggested to be replaced both look slightly curved, but this also looks intentional to me.


This helped me understand how the flaps work though and what was needed.


My roof would not go down. Really easy to see if the resolution will work if you have the same problem.


Open the boot. If either of the flaps have play in them, if you push them against the boot lid, and hear the microswitch click; then yes, this is your problem. If the roof is half open and stops, lightly (do not force) move the flap into the open position and if you hear the microswich again, then yes you have this problem.






The adjuster is the two nuts you can see in the pictures on what looks like the piston that moves the flaps. (yellow arrow on my plagiarised pic) Note that when you try to adjust this, the plastic tube that holds the worm drive will also move, and this makes a big difference to the relative position on the flap. (more on that later)


When I first reassembled I ensured I had the full range of adjustment to make the flap tight against the boot. This worked well but ultimately was a mistake. I could now get the flap tight against the boot and the roof started to move, however the flaps would not now fully extend.


The next time I made sure I resembled with the black nut half way between the two possible extremes.




Roof still fully up : - Put mechanism back together if you took it apart. It is not essential to take the flap off as previously suggested, and it is a pain and will require you to adjust for perfect positioning if you do. (see last comment)




I recommend before you order bits or take mechanism apart:


Loosen off the lock nut above the black nut (yellow arrow points at black nut).
Adjust the black adjustment nut (see picture) until the flap was closes against the boot, but not tight.... just until you hear the micro switch click, and light pressure on flap does not result in the microswitch unmaking.


Note - Less silver thread on view to you results in the flap moving towards the boot position.


Retighten the silver lock nut against the black nut.


The boot should now open fully.
If you have the problem where the roof is stopping half way, test the free movement on the flaps where it stops, knowing that this time, the flap is meant to be fully extended and making a different micro switch. It is possible to make adjustments at this point too, but be aware...making it too tight in the fully open position makes it too loose in the fully closed position.

I put my roof through the full cycle a couple of times, and found that although I left the flap a bit flappy against the boot lid when roof is up, it was now tight. It is clear that when making adjustment, that the outside of the ram swivels a bit (there is nothing to stop this) and that movement in itself is the same as moving the black adjustment nut. Unfortunately the only thing that really stops this movement is the natural tension on the cable so it would be difficult to predict when making your adjustment. In my case it worked in my favor when I left the flap a little loose.


Should this adjustment fail again I'll repost (the failure) and try the new bits. All mine looked perfect and no visible wear.




If anyone does take the leather bit off the flap.... don't put it back on again until you have your roof down. The plastic flap will need some adjustment with the two torc bolts for positioning before you click the leather cover to the flap back on....or you'll be taking it apart again to get the flap back off!

Last edited by Darrens; 06-19-2017 at 07:58 AM.
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Old 08-28-2017, 05:53 PM
  #53  
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Parts from Pelican @ $53. The SL was due for oil/filter change so I had my independent mechanic install them this morning @ $100. Top works perfectly! Well worth it since I have no bloody knuckles, yelled no curse words and read the newspaper in exactly the amount of time it took for him to install.
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Old 09-27-2017, 02:34 PM
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Smile Trunk Flap

Dealer told me estimate ~ $900
Thank you for your great advise... it worked but installation needs two people( holding and adjustment ) .....Now its working great... I order recommended parts from eBay cost me $57
great job guys i save lots of money
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Old 06-13-2018, 01:15 AM
  #55  
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Roof wont close on my sl55

thanks!k Mercedes quoted me $890 today. With your post and the one below, I made and adjustment and it works fine so far.
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Old 06-13-2018, 02:09 AM
  #56  
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Originally Posted by NikleinR6 View Post
If your Vario roof stops working one day, it could be that the trunk flap is not sitting tight against the trunk lid. Sensors monitor the positions of these flaps, and these sensors might not be tripped by a flap that is sagging too low. I never had problems with my roof not working, but after reading through various posts of others that had, i decided to check out the condition of my flaps. To my surprise my passenger flap was sagging quite a bit (my drivers side was fine). I then discovered that Mercedes released an updated part to resolve this issue. The new part is heavily reinforced and will resist bending much better than the original part.
Also, don't bother with the adjusting screws as they don't work very well for adjusting the tension of the flap. I ordered the new supporting parts from parts.com. The came as a pair, so i decided to install both sides. This way i will never have to worry about my top being stuck because of a silly cheap part.
Here are some pics and instructions for changing the parts.
The right side took 20 min. , and the left side took 10 min. because i new what i was doing after learning from the right. Basic tools are all that's needed, and very little skill.

Attachment 382822
Attachment 382823
Attachment 382824
Attachment 382825
Attachment 382826
Attachment 382827
Attachment 382828
Just got a quote from MB today to fix the roof of my SL55 for $890. Thanks to this post I fixed it tonight at a cost of my time only.
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Old 07-28-2018, 07:47 AM
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SL55 AMG
My problem is a little different but still flap related. I had to manually close the roof and in doing so manually operated the flaps by applying voltage to the pins in the wiring harness connector located just below the pump. The flaps move fine in the open direction or position they would be in with the top down, This maybe related to gravity assisting with this move as the trunk lid is not in its normal position for the roof to close. When reversing polarity to close flaps the motor is not strong enough to lift flaps back into position without a little help. My question is should the motor be strong enough to operate the flaps regardless of position of trunk lid?
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Old 07-28-2018, 10:34 AM
  #58  
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Originally Posted by whittle View Post
...should the motor be strong enough to operate the flaps regardless of position of trunk lid?
Yes, abosolutely.
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Old 07-28-2018, 11:40 AM
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What voltage source did you use? If you are using a 9v battery, it won't supply enough power.
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Old 07-28-2018, 09:02 PM
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Couple of pearls to speed the one person process

Thank you for the wonderful post. I found it to be a one person job if you perform the procedure by opening the top and stop the opening as soon as the trunk is up and the flaps close against the trunk lid liner. Other helpful items: The switch harness connector pulls straight out without any other maneuver. To make the new flap sit tight against the liner, loosen the lock nut, slip the new part into place, then rotate the new part until the gear inlay has no play, then place the flaps over the new gear part keeping it in the opposed position and tighten down the 2 Torx 30 screws.
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Old 07-28-2018, 11:09 PM
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SL55 AMG
To Rudeney's question I was using a 12 volt car battery that had a good charge. I would like to just replace the motor but can't find one anywhere.
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Old 07-29-2018, 10:30 AM
  #62  
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If it is a bad motor, this is it:

https://www.shopmbonline.com/oem-par...tor-2308201942
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Old 07-30-2018, 06:20 PM
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The motor wasn't bad the test leads I made up that had an old switch for a 12 volt fan was dropping to much voltage across the switch. Before I discovered that I pulled the motor off the drive assembly and ran it directly off of a battery with no switch, had a ton of torque. Put the motor back on wired it with no switch and it worked fine. Now the car is all put back together, top lock cylinder the original problem, repaired, trunk close assist working good, flaps good wife happy. Thank you MBWORLD
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Old 09-29-2018, 03:05 AM
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98 sl 500
Help - 06 sl500 - I hit the top open while moving 5 mph and it started to open - trunk started to raise 8inchs then stopped.. I tried to close it.. it moved an inch.. I pulled over put it in park and tried to open/close but it seems stuck with the trunk at 3inches open . the console switch produces the noise of a motor working in the trunk but nothing is moving, (on the up or down) pull of switch. Flaps are good... any ideas???
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