If you've ever considered converting your Mustang convertible's manual top to a power top but have hesitated because the job seems too technically involved, then Paul Gammerino from Mustangs & Fast Fords Orange County is going to show you how to do it. Paul asked if we'd like to cover a manual to convertible top conversion, something we've never done before in Mustang Monthly. We were only too happy to oblige.
Though a power top conversion might seem complex, there's really nothing to it. Manual tops get help from a couple of spring-loaded counterbalance cylinders, which make it easier to raise and lower the top by hand. When you convert to a power top, all you're doing is replacing these counterbalance cylinders with hydraulic lift cylinders, which are powered by an electric pump located behind the rear seat. That, plus a simple wiring job to get power to the pump, and you're in the thick of power top operation in a matter of hours.
Because we weren't able to get our cameras inside the convertible top well, we thought we would show you proper configuration of both counterbalance and lift cylinders in manual and power top applications. The lift and counterbalance cylinders have one attachment point at the main pivot extension plate and bracket inside the well. Cylinders are tied to the convertible top mechanism via a clevis pin, which always tends to come loose due to cotter pin failure or removal. Always install new nylon bushings and hardware along with plenty of white grease when you do a power top conversion.
1 To get started, lower the...
1 To get started, lower the top for improved access.
2 Mustangs & Fast Fords Orange...
2 Mustangs & Fast Fords Orange County (MFFOC) acquired everything needed to convert to a power convertible top. Most of these components are reproduced by Scott Drake Reproductions. Absolutely everything is here to get the job done.
3 The rear seat must be removed...
3 The rear seat must be removed to gain access to the convertible top well and pump location.
4 MFFOC technician Bill Hutton...
4 MFFOC technician Bill Hutton removes the rocker sill plates to make quarter trim panel removal easier.
5 After removing the screws,...
5 After removing the screws, the quarter trim panels are removed next to gain access to the convertible top wells.
6 There’s a convertible top...
6 There’s a convertible top hold-down latch on each side. Both are removed with a ½-inch socket.
7 Using a 1/2-inch socket...
7 Using a 1/2-inch socket and extension, two bolts are removed to free the counterbalance spring assembly. A rod-end at the convertible top mechanism must also be disconnected. All of this is performed with the top up once the quarter trim panels and rear seat are out.
8 Remove the counterbalance...
8 Remove the counterbalance spring assembly. Although spring pressure isn’t that great, take care to protect your eyes and face.
9 After chasing and cleaning...
9 After chasing and cleaning the bolt threads, the pump bracket is installed as shown. Unfortunately, it is not available as a reproduction. You will have to find an original in used condition.
10 The pump’s rubber mounts...
10 The pump’s rubber mounts have to be trimmed on one side for fastener access.
11 Pump installation is simple...
11 Pump installation is simple by working with two fasteners and four rubber mounts. You will need a ½-inch box end wrench.
12 The hydraulic lift cylinders...
12 The hydraulic lift cylinders use the same brackets as the counterbalance springs. Bushings are replaced and lubricated with white grease.
13 The hydraulic lift cylinders,...
13 The hydraulic lift cylinders, also known as actuators, are installed next. They have a plastic hydraulic hose connection at each end for propulsion one way or the other to raise or lower the top.
14 The hydraulic lines are...
14 The hydraulic lines are easy to understand because they’re already assembled for you. You will find that the pump-to-lift-cylinder lines must be routed to clear the top mechanism in each well outside of the window mechanisms.
15 Hydraulic lines are connected...
15 Hydraulic lines are connected to the lift cylinders. Line length quickly determines which line goes where. One line lowers the top while the other raises the top, with pressure going to one end of the lift cylinder or the other.
16 The electrics are simple...
16 The electrics are simple too. Here, the pump ground is connected. Pump power comes from a simple two-pin/two-wire lead that reverses polarity to reverse the pump motor.
17 MFFOC uses Adel rubber-lined...
17 MFFOC uses Adel rubber-lined clamps to retain the hydraulic hoses, which is not what Ford used but, after all, this is a weekend fun car and the clamps won’t be seen anyway. Note how the lines are routed out of harm’s way, clear of both the window and convertible top mechanisms.
18 Power comes straight from...
18 Power comes straight from the battery at the starter solenoid, with protection from a 20-amp circuit breaker. For authenticity’s sake, you can get power directly from the battery. If you want switched power, get your power from the ignition switch using the 20-amp breaker. Regardless of where you get power, you must always have circuit protection.
19 The convertible top switch...
19 The convertible top switch is located in the factory position on the instrument panel to the left of the steering wheel. You must be very careful with installation because once you’ve cut the dashboard, you’re stuck with the decision. Masking tape is used to protect paint.
20 The switch is connected...
20 The switch is connected to the power top harness, which gets its power from the battery and directs power to the pump. The harness is routed along the bottom of the dashboard above the lip and below the glove compartment.
21 Route the harness down...
21 Route the harness down the A-pillar to the rocker panel, then rearward to the bottom of the right-hand top well and over to the pump.
22 Once all electrics and...
22 Once all electrics and hydraulic hoses are safely connected, it’s time to bleed the pump. First, service the pump with power steering fluid until full. With lift cylinders disconnected from the top mechanism, the pump is cycled up and down until all air is out of the system. Because lines are clear, you can see air bubbles being purged. Add fluid as necessary. Cycle the pump until all air is removed.
23 After connecting the hydraulic...
23 After connecting the hydraulic lift cylinders, test the top for proper operation.