Pop Top Arm Repair

If you choose to use this information please understand that you do so at your own risk. Consult your Vanagon Bentley. Information here is based mostly on a 1981 Westfalia, but the wear points and assist construction are very likely the same for later model years.

The ends of the pop top push bar are prone to excessive wear. Each end is housed in a pivot point between the upper and lower arms. The end of each upper arm is narrow. Under normal use, this end cuts into the push bar posing the risk of it cutting through completely. The hole on this part of upper arm also wears as it rubs on the push bar ends. General opinion seems to be that these parts should be inspected and repaired sooner than later.
Parts description and normal operation.

The lower pop top arms contain a lift assist system; a cable and spring. A recent viewing of ETKA by the author, showed only one set of assist parts. It's likely assist parts were installed in each lower arm at time of manufacture. Each cable has a bolt shaped part on one end and "Z" termination on the other. The "bolt" seats at bottom of spring, the cable passes through spring, exits end of lower arm, follows the curve with the "Z" securing to a hole. As the top is lowered, the cables pull on the springs. As the springs expand and tension, some of the tops' weight is effectively "taken off". As the top is raised, the springs contract and relax which helps the user push up and forward on the push bar. A failed cable(s) may not be detected by the owner. They may not know of these parts and/or have grown accustomed to the weight. The pop top is typically closed most of the time leaving the cables and springs under tension.

Strut assembly removal: method 1.

With the top down, bind the upper and lower arms together by passing a suitably sized wire or rope through upper hinge then around lower and upper arms. This wire or rope needs to securely bind the arms together. Failure to do so could result in arms suddenly flinging apart. If more work room is needed, the top can be resting but not latched. Consult Bentley for fastener removal. Remove fasteners at upper and lower bracket hinges, raise and safely support top high enough to provide L/R movement for strut arm assembly removal, remove assembly.
Strut assembly removal: method 2. Untested by author.

Determine if strut assembly can be safely removed as one piece or if disassembly in situ is required. Raise top completely. The top is heavy. Support securely with temporary support. Tension in springs is now almost totally released and stop pins at top of lower arms prohibit further movement. Remove fasteners and/or hinges. If temporary support is not in the way, there may be enough room to take out strut assembly as one piece. If not, before removing fasteners at top of upper arm, on one side, allow arms to collapse slightly, (this tensions spring slightly) remove the stop pin on upper arm, allow lower arm to release any remaining tension. Remove "Z" end of cable from hole, remove nut/bolt on push bar, tap arms off end of push bar.
With assembly on bench, disassemble as per steps above. Check cable(s) for excessive wear. They do fail. When a cable fails, and user is lowering or raising top, weight of top suddenly increases. Inspect ends of push bar and hole in big end of upper arm for wear. A bushing made of bronze or copper can be epoxied in hole on upper arm. Better yet, weld in a steel bushing. The bushing will act as a bearing and spread out pressure. Lubricate these parts. Though likely not needed, the author epoxied a piece of 5/8" bolt into the push bar ends to add support.

Authors pics/text of repair: picasaweb.google.com/musomuso/PopTopStrutCableAndSpringEtc#
David Beierl's pics/text of repair picasaweb.google.com/dbeierl/VanagonPopTopHingeTroubles#

Possible issues and tips.

Needle nose vice grips carefully applied to carriage bolt heads can assist removal. Clean top and bolt heads where they meet, caulk bolts, install. Open driver side slider for access to carriage bolt nuts. Pivot pin push nuts may get deformed during removal. Both sizes of pivot pin and push nut can likely be sourced from a generic auto parts store in SAE size. If using method 2, pre plan for some way to safely lower the top once strut assembly is removed. The top is heavy. Preplan for a safe and slow way to release the arms once strut assembly is removed. They are under a fair amount of tension. Be aware that you have to bring the arms back together and tie up if installing as per first removal method. If a cable is broken, a possible solution: picasaweb.google.com/musomuso/PopTopStrutCableAndSpringEtc#5505035759536410866

Installation of assembly: method 1.
Pop top safely raised and supported to allow room to put assembly into position, install lower fasteners, slowly release the arms, line up upper hinge (top may need to be lowered for this to line up bolt holes). Install Phillips screws most of the way in, caulk the carriage bolt heads. Install bolts mostly tight, final tighten Phillips then bolts.

Installation of assembly: method 2.
Fold arms and tie together as per removal method 1. Lower pop top, but leave it open enough so assembly can be put into position. Support top properly. Install lower fasteners, slowly release the arms, line up upper hinge (top may need to be lowered for this to line up bolt holes). Install Phillips screws most of the way in, caulk the carriage bolt heads. Install bolts mostly tight, final tighten Phillips then bolts.