I seem to be springing leaks everywhere. I just fixed the power steering and now one of my convertible top cylinders is leaking through the shaft seal. I could, of course, just order a new one, but where would the fun be with that? So, stay tuned as I attempt to demonstrate a rebuild.
STAGE ONE: DISASSEMBLY
The internal workings of a top cylinder are surprisingly simple, and absent serious physical damage to the shaft (e.g., substantial rust) or damage to the cylinder tube (e.g., dents), the only real obstacle to DIY rebuilding one is the fact that the cylinder tube is permanently crimped onto to the cylinder head. In other words, the only way disassemble it is to cut it open. So that’s exactly what I did:
Start by carefully cutting around the cylinder tube wall right at the shoulder of the crimped edge as shown in the above picture. The tube is aluminum and is quite thin and it cuts easily. You want to cut ONLY the tube, not the material underneath so your cut is only about 1/32nd inch deep. Also, if you clamp the cylinder in a vice like I did, do not tighten it very much or you could dent the tube, which will ruin it.
Once you’ve cut through the thin layer of the tube, get a grip on the head with a channel lock or some other violent tool and simply twist and pull the head and guts out from the tube.
