Convertible Top Problems.... Finally some answers (archive)

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Just today, "Spritzer" (98/2.8) got her THIRD beige convertible top installed under warranty. Remember the word biege, it plays an important part in this story later on. The dealer once again only replaced the "skin" and did nothing to modify or replace the framework, leading me to believe the same problems will occur again. This is no laughing matter, because after the warranty expires, these tops are about $1600 installed!!

For several weeks I have been emailing the company that produces the tops on our Z3s for BMW (ASC Global). Three times I sent emails to their marketing dept. with no answers. Then thanks to Steve Fox who saw my prior posts on this board, gave me the name of the companys owner, Mr. Heinz Prechter. Addressing the email directly to him did the trick! Thanks Steve!

AFTER READING THIS, IF YOU HAVE HAD PROBLEMS WITH YOUR TOP, PLEASE POST A REPLY TO THIS MESSAGE, SO WE CAN DETERMINE JUST WHAT'S HAPPENING PLEASE!!! STATE THE PROBLEM. THANKS!

I understand that your company produces the convertible tops for the BMW Z3 roadster. I own a 98 BMW Z3 that I purchased new with only 22,000 miles currently on the vehicle. I have had extensive problems with the top.

1. The material has pulled away from the plastic rear window in the lower driver's side corner at the window.
The dealer could not repair this, nor the factory reps at the plant.

2. The top has "L" shaped wear marks on both sides of the top in the rear below the window. Evidentially, when the top is down, some piece of framework rubs against the top material causing this wear. Another Z3 owner told me his had the same problem and actually wore all the way through. I don't really even have the top down all that much. If I had my top down all the time, the material would be worn through in about a year or less.

3. My dealer agreed to replace the top under warranty. When the new top was all installed, the dealer realized that the top had a flaw in it on the top surface. It is a very noticeable cut mark about an inch long. There is like a matching white mark on the inside at the same spot. Where was the inspector before this top was shipped? Now I have to go back in again, to have the third top put on and be without my car for two days again!

4. What concerns me most is that I see nothing different that is being done with my warranty work. All they are replacing is the convertible cloth material, not the framework, or making any modifications to it. I'm afraid
that the new top will wear in exactly the same area again just as rapidly.

Your press release on your website states you are going to "develop and produce the complete roof system of the next generation BMW Z3 roadster." Will this be a different design that will correct the flaws in the original ones?

Thank you for you comments regarding the BMW Z3 topstack. It is
unfortunate that you have experienced the two issues you mention below, but
please know that these issues are not unknown to us. We have, in fact,
been working on these issues for some time and I am pleased to tell you
that measures have been implemented (both design and manufacturing changes)
to correct/mitigate them. I will address each of your concerns separately
as you have detailed them. Note: These two issues are strictly Topcover
related and in no way are affected by the topstack frame.

1. The issue regarding the topcover material pulling away from the rear
window can be caused by a number of factors. However, we believe we now
have a solution in place that virtually eliminates this issue.
Additionally, due to the sensitivity of this window, it was designed to be
replaceable should it be damaged. The most probable reason the factory
reps could not repair it is that they were probably not using a "Service"
rear window. This is an important distinction since it is manufactured
differently than the OEM rear window. Why your dealer could not repair
it, I do not know. Although I cannot guarantee 100% that it will not
happen again, I can tell you our tests of solutions have been extremely
positive.

2. The wear issue you mention is due to the manner in which the
topcover material folds as the frame actuates. This folding is primarily a
factor of the material (weight, thickness, stretch, cut pattern, sew
pattern, etc.). In fact, I am guessing by the location of the wear marks
that you have a Beige colored top. This top has a different cut/sew
pattern than the black material due to these material properties. Wear
marks in this area (below the backlite area) are almost non-existent on
other colored tops.

We have implemented changes that will mitigate this issue. Please note,
however, that almost all wear marks you see on a topcover are caused by the
material rubbing against itself while the top actuates. This can never be
completely eliminated.

3. I cannot say what caused the cut mark on your replacement top, but I
can say the likelyhood that it was shipped from one of our facilities with
that condition is very low. Not only are the topcovers inspected by us
prior to shipment, but they are inspected by BMW once they are received by
them. The installation process for a topcover is not easy. Many things
can happen during this process to damage the topcover and I suspect this is
where the damage occured. However, without being able to see the topcover,
it is impossible to determine the root cause of this cut.

4. As I mentioned earlier, the two issues you have had with your top
are directly related to the Topcover and not the frame. This is why your
dealer did not replace the topstack frame assembly. Doing so would not
alleviate your problems.

Again, I am sorry that you have experienced these problems with your
topstack, but know that we have fixes in place and are monitoring their
effectiveness. As with any supply system, the replacement topcover you
receive may not be the latest level, so please have patience should one or
both of these issues develop again.

And yes, we are currently developing the Next Generation Z3 Topstack
(along with Edscha-Scharwecter in a Joint Venture). Rest assured, that
during its design/development we will incorporated all "Lessons-Learned"
from this and other programs in an attempt to produce the highest quality
topstack on the market.

If you have any further questions, please don't hesitate to email me
directly at: lewisde@ascglobal.com

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