Ford Escort Manual

Power-operated folding roof components - removal and refitting
Bodywork and fittings / Power-operated folding roof components - removal and refitting


Hydraulic rams Removal
1 Remove the rear wheelhouse covers with reference to Section 32.

2 Mark the two hoses connected to the ram as a guide to reassembly, then remove the circlips securing the ram to the two studs on the framework.

3 Release residual pressure in the system by opening the filler plug on the pump body.

4 Loosen the hydraulic unions on the ram, then remove the ram from the studs and lay it in a suitable container in the boot. Undo the unions and catch the hydraulic fluid in the container (see illustration).

24.4 Power-operated folding roof hydraulic ram assembly - hydraulic unions
24.4 Power-operated folding roof hydraulic ram assembly - hydraulic unions (arrowed) A and B Upper and lower clips

5 If the unions are to remain disconnected for any length of time, cover the ends to prevent dirt entering the system.

Refitting
6 Refitting the ram is a reversal of removal, noting that the large circlip is fitted to the lower stud.

7 On completion, fill and bleed the system as described in Section 23.

Hydraulic ram upper pivot stud Removal
8 Should the hydraulic ram pivot stud break in service it can be renewed as follows.

9 Open the tap on the hydraulic pump, then manually open the roof halfway.

10 Using a mole wrench, remove the broken end of the pivot stud from the framework. If the remaining stud is too short it may be possible to remove it using a proprietary stud extractor kit.

Refitting
11 De-grease the threads on the new stud, apply locking compound to them, then fit the stud and tighten it securely.

12 Refit the hydraulic rams as described previously in this Section.

Pump
Removal
13 Disconnect the battery, then pull down the pump cover in the boot and open the bypass valve by 90 to 180 degrees. Do not open it any further.

14 Open the roof manually.

15 Remove the floor panel and left-hand wheelhouse panel from the boot. This involves propping open the boot lid and disconnecting the supporting gas strut from the lower balljoint.

16 Release residual pressure in the system by opening the filler plug on the pump.

Tighten the plug when the pressure has been released.

17 Disconnect the electrical lead to the pump.

18 Remove the nuts securing the pump to the boot floor, and place the pump in a suitable container to catch the fluid which will be spilt when the pump hoses are disconnected.

19 Mark the hoses as a guide to reassembly, then undo their connections (see illustration).

Cover the open ends if they are to remain disconnected for any length of time.

24.19 Power-operated folding roof fluid pump removed from mounting with hoses
24.19 Power-operated folding roof fluid pump removed from mounting with hoses marked

A Filler plug
B Hydraulic unions
C Wiring plug
D Pump mountings

Refitting 20 Refitting is a reversal of removal.

21 On completion, fill and bleed the system as described in Section 23.

Hydraulic hoses
Removal
22 Renewing the hydraulic hoses involves disconnecting the relevant hose connections from the pump or ram (see earlier paragraphs), noting its routing, and where it is clipped or taped to other components (see illustration).

24.22 Routing of power-operated folding roof hydraulic hoses
24.22 Routing of power-operated folding roof hydraulic hoses

Refitting 23 Refit in the reverse order to removal.

24 On completion, fill and bleed the system as described in Section 23.


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