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How to Repair the Roof of the Smart 450

Model: Smart Smart 450 - Years 1998-2007
Part: Convertible top

It often happens that during the closing and/or opening of the roof, it struggles to reach the end of its travel and latch due to wear on the gears of the motors that operate and drive the mechanism. You can permanently solve this problem by replacing the original gears with rebuilt ones made of hardened steel, which are much tougher and more resistant to wear. The replacement is straightforward as the motors are easily accessible and removable, located at the rear of the roof, hidden by specific caps. Once the motors are removed, use a puller to take out the old gear and insert the new ones.

Updated on 23 February 2026 by ScegliAuto

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Lift the vehicle on suitable axle stands, remove the front wheels, and then the front bumper and grille. Proceed to remove the front headlights; drain the coolant, remove the intercooler radiator and the hoses connecting it to the intake system. Position the new intercooler radiator in the grille, temporarily securing it with cable ties, and mark with a marker the part of the metal that needs to be removed to allow the new hoses to pass through. Cut the marked portion of metal and apply a gasket to the edge. Remove the inner cover of the bumper and position it near the radiator to identify any interfering parts to eliminate: again, apply a gasket to the edge of the cut. Create brackets for securing the new radiator and proceed with the installation of the connecting pipes from the radiator to the intake, shaping and connecting them appropriately. Finally, reassemble the bumper, headlights, and grille.

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by ScegliAuto

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