Golde/BMW Sunroof Hinge Repair Using the 2002 FAQ kit

[dlacey]

Golde Sunroof Cable Hinge

From 1965 until about 1985, Golde sunroofs were a factory option on various European cars. They were a factory-installed standard sunroof option for the BMW 2002 series, BMW Neue Klasse, BMW E3, and BMW E9 cars.

 

The sunroof cable (No1 in the above diagram) pushes&pulls the sliding roof panel, in the BMW application the hinge/ends of these cables are a plastic moulding which takes the full force of all movement actions. These ends slide along the alloy track in the roof:

• pulling/pushing the roof panel.
• acting as the fulcrum point for the rear panel hinge.
• engaging with a spring in the roof to "flip up"the hinge and complete the closing action of the panel.

Unfortunately these plastic parts break due to stress and old age, rendering the sunroof inoperable. New cables are available, but the plastic ends in these new cables seem to break more easily than the originals.

 

The Kit

We have developed a simple kit with precision CNC machined alloy pieces that enable your original Golde cable hardware to be salvaged and put back into use. The high quality metal parts will not degrade - providing a long-term fix for your sunroof.

 

The kit consists of

• Two anodized alloy end pieces 
• Two sleeves 

The two end pieces are identical but are assembled 'mirror image' in the application.

Get your Golde Sunroof Cable Hinge Repair Kit today at the 2002 FAQ Store!

Assembly

Assembly requires a small bench vise, some wire wool/abrasive paper to clean up the salvaged parts, a junior hacksaw & pliers. Basic soldering skills are needed to fit the securing bullet sleeves on the cable ends.

 

1) Photograph or draw the old hinge to make clear which side the long pin goes, and the orientation of the alloy rotating part (it rotates 90 degrees as sunroof closes) - note that although the hinge pieces are identical each side, the position of the long pin and the orientation of the rotating alloy hinge piece are different - take great care not to confuse the assemblies!

 

2) The plastic hinge is held on to the cable by a crimped 'bullet' on the cable end - we need to remove that bullet without damage to the steel cable inside. If you have a Dremel or other small grinding tool, this might be a good way to cut the bullet open. Otherwise, it can be done with a small hacksaw and some force:

 

 

 

 

3) Secure the steel pin in vise jaws and pull/twist on the plastic hinge body to extract the pin:

 

4) Using a small drift or by breaking the old plastic hinge, retrieve the alloy rotating part & the hinge pin.

 

Use fine wire wool & sandpaper to clean-up the end of the long steel pin and the whole of the small hinge pin. Use a small wire brush to clean the end half-inch of the sunroof cable - where we will secure the new bullet.

 

5) Refer to your picture or drawing and orientate the new hinge with the long pin, rotating piece and hinge pin.

 

6) Fitting the alloy rotating part & hinge pin.

Careful inspection of the new hinge will show that the hinge pin will slide into one side of the hinge, but is an interference fit in the other side... this is by design, so that the hinge pin can be press-fit into position...If your pin will not slide-in either side, try cleaning it a little more. Double-check orientation of the alloy rotating piece, and slide the hinge-pin through one side of the new hinge. 

 

Use a bench vise to push the hinge pin into the interference fit side of the hinge. Make sure the 'ear' of the hinge is properly supported as the pin is pushed home to prevent distortion of the hinge.

 

 

 

7) The steel pin is a similar interference fit into the new hinge body - make sure the end of the pin has no burr and the area to be inserted is properly clean - suggest mount the pin in an electric drill & spin it while burnishing with some fine sandpaper.

Double-check your original pic/drawing for orientation again!

 

The exact depth this pin goes into the hinge body is not super important - if it wont go in, try a bit more burnishing with sandpaper... as long as it's pressed-in at least quarter inch then it will function fine.

 

8 ) Attaching the cable to the new hinge.

The original bullet was crimped in position - that's difficult to do without a proper crimping tool - if you just squeeze the bullet with pliers it will go oval and no-longer slide in the alloy sunroof track. It needs to be solidly attached - all the force of the handle winding when closing the roof is being taken by these bullets.... you don't want one falling-off on a dark & stormy night. To secure them solidy without deformation, we are gonna solder them on. To do this you need some solder - the fine flux-cored type used in electronics - (not the plumbing stuff!), some additional 'solder paste'/flux to spread on the cable end so the solder will 'wet' it, and a small hobby torch/flame - the type that has a disposable butane cigarette lighter inside.

 

Mount the cable in the vise, with the cable end sticking vertically upwards. Slide the new hinge assembly into position (check orientation again!), then put a small amount of flux on the cable end.

 

Take the new bullet - note one end is opened wider than the other - dip the wide end in flux and then push that onto the cable. Now heat the side of the side of the bullet with the butane torch, after a few seconds start feeding solder into the exposed top open end of the bullet... heat & feed until the solder forms a 'blob' on the end of the bullet. Allow to cool slowly.

 

 

 

 

 

Once cooled, clean-up any excess flux and check the bullet is firmly secured on the cable end.

 

 

9) Your cables are now ready to re-fit to the car - and you can be confident they will provide many years of service without risk of breakage.

 

10) As you reassemble your roof, take a look at the condition of the drive gear that engages with the cables - this can get worn and cause the gear to 'jump', the teeth of the gear getting mis-shapen... good news is that the gear can be replaced: it's Golde Part No 313877407 - you'll find it available from VW specialists as a similar Golde roof was fitted on VW cars of a similar era.

 

Where to buy

Get your Golde Sunroof Cable Hinge Repair Kit today at the 2002 FAQ Store!

Kit includes 

• Two anodized alloy end pieces 
• Two sleeves 

The kit is offered at $120, with parts to repair two cables (one sunroof). This is significantly less than the price of one replacement cable from Golde/BMW and provides a high reliability solution that will last forever even in extremes of heat & cold.

 

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[66Vette]

This is fantastic news.  I have a sunroof car and the parts availability is a little scary.  Nice to see someone making some quality replacement parts!

[OldRoller]

Excellent product and explanation of install. Beats hunting down a pair of Volvo cables with the metal slides and their extravagant cost!

Well done!

[bublinki]

Once again 2002FAQ comes through in making repair and upkeep of these vintage beauties, a snap.

Thank you, thank you to all of those involved in producing these parts!😑

I was just looking online for replacement cables and cost is for used cable is easily over $200.

 

[JsnPpp]

Seriously!? This is fantastic. Am stunned - keep up the great work @dlacey

 

I will order a kit!

 

Jason