DIY Network

1962 Fort T-Bird Restoration: Convertible Top, Part 2 From "Classic Car Restoration" episode DCR-308

	Among the car's unique features, the T-bird converts from a convertible to a 2-seat roadster by means of a removable tonneau cover.
	The '62 T-bird's trunk lid raises and lowers to permit concealment of the convertible top.

In this segment, work continues on the convertible top with inspection and service of the hydraulic parts, switches and relays.

Materials:

Standard automotive tools (socket-wrenches, screwdrivers, nut-drivers, etc.)
Spray lubricant
Spray contact-cleaner

Note: This is a summary of steps included in the automotive restoration procedures shown in this episode of Classic Car Restoration. These are general guidelines for restoration procedures on this particular make and model of vehicle, and for the level of restoration selected for this project. There may be variations in procedures depending on model, condition of vehicle, level of restoration undertaken and the types of replacement parts or upgrade kits selected. Always follow proper safety precautions, and read and follow manufacturer's guidelines, diagrams and safety notices that come with any replacement parts or kit that you select.

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Convertible Top: Servicing the Hydraulics and Switches

One of the most distinctive attributes of our '62 Thunderbird sports roadster is its folding power-top. Preceding our T-bird's folding top, in 1957 Ford wowed the automotive industry with a car called the Skyliner which actually had a retractable steel-roofed hardtop. The metal top folded down into the trunk and the Skyliner became a convertible (figure A). This elaborately engineered feature was ahead of its time, and these cars were only made from 1957 to '59 before being phased out. But the technology from the Skyliner found its way into cars like our Thunderbird.

The 1962 Thunderbird sports roadster possesses a convertible that folds down and is concealed inside the trunk. The whole thing closes down and is hidden from view beneath a sleek trunk-lid (figure B). This is made possible through a complicated system of electric and hydraulic circuits that work together to create a sort of mechanical ballet.

Figure A

Figure B

• Because of the complexity of this system, a fair amount of maintenance is required. For our restoration, the first thing we do is inspect the hydraulic cylinders and hoses to make sure there are no leaks (figures C and D). The hydraulic system for the top runs on heavy-duty brake fluid.You'll be able to spot leakage because of the presence of fluid on surrounding areas. Fixing leaks in this system is usually not terribly difficult. Thunderbird clubs are an excellent resource for replacement hoses or parts if needed.

  Figure C

  Figure D

  
  
• The electrical system for the convertible top is rather complicated and employs a series of stop-switches (figures E and F) that keep the motors from crashing into each other as the top goes up and down.

  Figure E

  Figure F

  
  
• The stop-switches are critical to the operation of the top, but they may corrode over time. When servicing the top, spray the critical locations with a bit of contact cleaner and lubricant, making certain that the contact cleaner penetrates down into the switches (figures G and H). Contact cleaner is available at electronics stores.

  Figure G

  Figure H

  
  
• Ford was innovative in their use of electric motors to operate the moving parts of the convertible top. One motor mounted beneath the lid (figure I) controls cables that turn screw-jacks (figure J) which, in turn lock the car's lid down into the quarter panels. Another motor drives a 90-degree gear box, which causes the entire rear panel to fold down when it's cued to do so by the electrical circuits. Another electric motor drives the hydraulic fluid pump to provide pressure to operate the hydraulic lines on this car.

  Figure I

  Figure J

  
  
• The relays that control the system (figure K) are arranged in banks of four or five per side. Essentially these are breaker points that are cycled off and on by the limit switches to tell the motors when to start and stop running. The electronic relays themselves can be a little finicky. To service them we remove each one individually, spray a little contact cleaner and lubricant to keep it from corroding (figure L), and reinstall.

  Tip: A recommendation from the enthusiasts at the T-Bird clubs: If there's trouble with the top, check the relays first. The 1962 Thunderbird shop manual has specific information and instructions pertaining to problems that may arise with respect to the complex convertible top.

  Figure K

  Figure L

  
  

  The factory service manual is a vital tool in the ownership of a car as elaborate as this Thunderbird. Instructions and diagrams are helpful with respect to the convertible top's framework and system of switches and hydraulic controls to raise and lower it.

RESOURCES :

Classic Car Restoration Guide: The Complete Illustrated Step-By-Step Manual
Model: 1850108900
Author: Lindsay Porter
Order this book from Amazon.com
Haynes Publishing

Classic Car Restorer's Handbook: Restoration Tips and Techniques for Owners and Restorers of Classic and Collectible Automobiles
1557881944
Jim Richardson
(November 1994)
To order this title from Amazon, click here.
H.P. Books

Thunderbird Restoration Guide, 1958-1966 (Motorbooks International Authentic Restoration Guides)
by William Wonder
Published by Motorbooks International, June 1997
ASIN: 0760303908
To order this book from Amazon.com, click here.

Illustrated Thunderbird Buyer's Guide (Motorbooks International Illustrated Buyer's Guide)
by Paul G. McLaughlin
Publisher: Motorbooks International (July 2000)
ASIN: 0879388706
To order this book from Amazon.com, click here.

GUESTS :

Keller Wallace
Keller Wallace Street Rods
Volunteer Street Rod Association
Knoxville, TN