California T5 (2006) pop top hydraulic strut failure issue

[edrch]

Hi all,

Reasonably new to this game (since April), so be gentle please...

Yesterday, whilst raised, one of the pop top hydraulic struts (driver's side) on our T5 failed magnificently with a large bang, blowing the cap off one end and spraying fluid/oil all over the canvas and back of the van. The roof buckled alarmingly to one side and in order to address the issue, I quickly tried to lower it using the console panel in the cab. Made a little bit of noise, but there was only a small response and that was not from the 'good side' of the van, and made the roof twist further. Tried the manual method - removing the console and cab light fitting and use the screw fitting to lower it. Again, no response - using that did nothing.

In the end, and in slight desperation, my wife used the console again to lower the pop top, which did work reasonably well, although it required some manual manipulation from me at the roof and, understandably, the mechanism made some alarming sounds. The roof is now sitting almost flush, just very slightly proud on the driver's side (with a tuft of canvas sticking out at the back end of the van). Problem is, the console thinks that the pop top is still raised. I need to drive to get the van to get the roof fixed (a 30 mile trip) and was planning to ratchet the roof down at the front, just to be on the safe side, and very much take my time driving to the garage. My main question is will the van struggle to make it - as in, will the console kick up a fuss? I started the van earlier and the display bleeped briefly and then went off (although the console still thinks the roof is up). I'm hoping that as it's an older California (2006) it might be more forgiving to me. I haven't reset the console yet - that's the only thing I can think to do before heading off.

Any thoughts, help!

 

[WelshGas]

Hi all,

Reasonably new to this game (since April), so be gentle please...

Yesterday, whilst raised, one of the pop top hydraulic struts (driver's side) on our T5 failed magnificently with a large bang, blowing the cap off one end and spraying fluid/oil all over the canvas and back of the van. The roof buckled alarmingly to one side and in order to address the issue, I quickly tried to lower it using the console panel in the cab. Made a little bit of noise, but there was only a small response and that was not from the 'good side' of the van, and made the roof twist further. Tried the manual method - removing the console and cab light fitting and use the screw fitting to lower it. Again, no response - using that did nothing.

In the end, and in slight desperation, my wife used the console again to lower the pop top, which did work reasonably well, although it required some manual manipulation from me at the roof and, understandably, the mechanism made some alarming sounds. The roof is now sitting almost flush, just very slightly proud on the driver's side (with a tuft of canvas sticking out at the back end of the van). Problem is, the console thinks that the pop top is still raised. I need to drive to get the van to get the roof fixed (a 30 mile trip) and was planning to ratchet the roof down at the front, just to be on the safe side, and very much take my time driving to the garage. My main question is will the van struggle to make it - as in, will the console kick up a fuss? I started the van earlier and the display bleeped briefly and then went off (although the console still thinks the roof is up). I'm hoping that as it's an older California (2006) it might be more forgiving to me. I haven't reset the console yet - that's the only thing I can think to do before heading off.

Any thoughts, help!

Either use the VW Velcro straps or a ratchet strap as you mentioned to hold the front down. The Roof Console might alarm but no harm will come. Resetting the Roof Console won’t do anything to stop the Alarm.

 

[edrch]

Either use the VW Velcro straps or a ratchet strap as you mentioned to hold the front down. The Roof Console might alarm but no harm will come. Resetting the Roof Console won’t do anything to stop the Alarm.

Thanks WelshGas - you've calmed my nerves a little, thank you. I honestly didn't know what else I could have done with the pop-top. It had to be lowered, for the van to be driven. Not sure if it would have been safe on the back of a recovery lorry either and I wasn't able to find any mobile camper engineers to help. I just hope I haven't done too much damage to the mechanism. 19 year old van technology, can't beat it!

 

[WelshGas]

Thanks WelshGas - you've calmed my nerves a little, thank you. I honestly didn't know what else I could have done with the pop-top. It had to be lowered, for the van to be driven. Not sure if it would have been safe on the back of a recovery lorry either and I wasn't able to find any mobile camper engineers to help. I just hope I haven't done too much damage to the mechanism. 19 year old van technology, can't beat it!

I believe the Hydraulic ram construction was change because of this problem occurring on earlier vehicles. It might be worth considering having both rams changed to avoid this happening on the other side in the future.

 

[edrch]

I believe the Hydraulic ram construction was change because of this problem occurring on earlier vehicles. It might be worth considering having both rams changed to avoid this happening on the other side in the future.

I am definitely getting both rams changed during the repair job, although I fear it may bankrupt me - I can't deal with sorting this again. Is it worth me flagging with VW (a recall situation?) or just something I take on the chin, financially?

 

[WelshGas]

I am definitely getting both rams changed during the repair job, although I fear it may bankrupt me - I can't deal with sorting this again. Is it worth me flagging with VW (a recall situation?) or just something I take on the chin, financially?

I don't think there was a recall as it was not that common a problem and the company that makes the rams just changed the design/manufacturing process over time.
The rams weren't specific to the California.
Internet concensus is 15 yrs and such systems may need refurbishment or replacement depending on usage.

 

[yanathem]

Buy the parts and fit the rams yourself.
Thread 'How to fill hydraulic reservoir for roof pump?'
https://vwcaliforniaclub.com/threads/how-to-fill-hydraulic-reservoir-for-roof-pump.41813/

 

[flying banana]

Tie the roof down. Somehow . You will have lost the hydraulic lock effect. The bonging sounds, ignore them and drive. It will be fine. The canvass stuck out the back i wouldnt worry about either. Can you just turn the panel off?

 

[crookrise]

If youve had the panel out just unplg it to stop the bonging ?
Just to add your roof will not be locked down as the rams, once roof down, engage a locking bar. Use your tie down straps

 

[Bobo]

Hi. We had problems with leaking rams on a 2007 van. I managed to top up the pump which worked for a while ( was a tricky and nerve racking job). I believe rams are easier to change but didn't feel confident enough. I booked in with Richard Milton/ Kernow Transporters and he sorted it (rams, pump and bellows). Not cheap but worth it for us. Picture on my post of finished job. Also Richard explained that the pump/ rams operate up and down and forwards/ backwards at the end to lock the roof hence the inability to lock when no fluid in the pump

 

[secret lemonade drinker]

You could consider going manual ( like a beach). I know a couple who did this on a T5 California and think it a lot easier, simpler

 

[edrch]

Update on this, should it impact anyone else:

I managed to get the van down the M4 to Bristol Caravans and Motorhomes, who were brilliant (shout out to Nick, incredibly knowledgeable). After eventually sourcing two rams from VW, they were installed in the workshop, although the job was reportedly not easy to do. The roof had to be propped up, the rams changed (reasonably straightforward) and the hydraulic fluid replaced, which was messy and difficult due to accessibility of the reservoir. The battery had to be disconnected overnight as the 'roof open' alert couldn't be cleared on the control panel, even after resetting it. The second ram was on its last legs too and was likely to go in a short period of time.

I'm glad it's all sorted, although I need a decent trip in more clement weather to try the rams out again and restore my confidence in them (a two year guarantee helps a little). Not a cheap repair job, as it turned out, and the poor old control panel has received a bit of a battering as it had to be removed as part of the work. No recall from VW regarding the rams either, according to Breeze in Poole.

Thanks for words of advice from other posters here, much appreciated.