Body Cargo Cover Repair Estimated reading: 4 minutes Contributors Overview This procedure guides you through repairing the cargo cover on all your Porsche 944 S / S2 variants (16-valve engine) when it stops retracting properly. The issue is usually due to a broken coil spring or the spring detaching from the plastic end piece in the retracting mechanism. Fixing this will restore the cover’s ability to roll up smoothly, keeping your cargo area tidy and functional. Pink and blue text represents links to additional resources, tools, parts, and partner websites. Tools Required Drill Drill bit set Punch Rivet gun and rivets 10mm (3/8 inch) wrench (for the large screws) Coat hanger wire (to make a hand crank) Step-by-Step Procedure Step 1: Roll Up the Cargo Cover Carefully roll the cargo cover shade into its assembly by hand. This prepares it for removal and prevents damage during the process. Step 2: Remove the Cargo Cover Assembly Locate the two large screws securing the cargo cover assembly behind the rear seat—one near each end, about 1 inch (2.5 cm) from the edges. Use a 10mm (3/8 inch) wrench to remove both screws. Lift the entire shade assembly out and place it on a large table or countertop for easier access. Step 3: Remove the Passenger-Side End Cover Find the plastic end piece cover on the passenger side of the assembly, held in place by a pop rivet. Use a drill with an appropriately sized bit to carefully drill out the pop rivet. Take care not to damage the surrounding area of the plastic end cover. Remove the end cover once the rivet is drilled out. Step 4: Extract the Roller and Shade Slide the roller and shade out of the assembly through the open end where the cover was removed. With the roller and shade out, carefully unroll the shade by hand, watching for any tears. Step 5: Inspect and Separate the Shade from the Roller Examine the roller—a hollow silver metal shaft with a slot along its length and white plastic end caps on both ends. Try to gently slide the shade out of the slot in the roller. If it resists, stop to avoid tearing it and move to the next step. Step 6: Remove the Spring-Side End Cap Locate the white plastic end caps pressed into each end of the roller. The metal shaft is dimpled in three places to secure each cap. Select a drill bit matching the dimple size and carefully drill out the three dimples on the end cap with the flat tip (attached to the spring assembly). You’ll slightly drill into the plastic, but that’s fine for now. Pull the end cap out, revealing the central shaft and large coil spring inside, covered by a brown paper sleeve. Remove the paper sleeve and set it aside for reassembly. Step 7: Remove the Shade (If Not Already Done) If the shade is still attached, slide it out of the roller’s slot now that the end cap is removed. Step 8: Inspect and Repair the Spring Check the spring and plastic end piece. The spring’s end may have detached from the end piece or could be broken—this is the most common issue. If the spring is broken, heat the end with a heat source (like a torch), bend about 1/8 inch (3 mm) into an “L” shape, and let it cool to fit back into the plastic end piece. If the spring is just detached, reattach it securely to the end piece. Step 9: Reassemble the Roller and Shade Slide the shade back into the slot of the roller. Replace the brown paper sleeve over the spring and shaft. Insert the spring and end cap back into the roller. Use a punch to create new dimples next to the drilled-out spots to secure the end cap. Wind the spring inside the roller 10-15 revolutions using a hand crank made from coat hanger wire (fingers won’t work for this). Slide the roller and shade back into the assembly. Step 10: Reattach the End Cover Place the passenger-side plastic end cover back onto the assembly. Secure it with a new pop rivet using a rivet gun. Step 11: Reinstall the Cargo Cover Assembly Position the cargo cover assembly back behind the rear seat. Fasten it with the two large screws, one at each end, using a 10mm (3/8 inch) wrench. Post Procedure Checklist Check that the cargo cover retracts and extends smoothly without sticking. Ensure the assembly is securely mounted with no loose screws. Inspect the shade for any tears or damage caused during repair. Sources Clark’s Garage Pelican Parts Porsche 944 Workshop Manual, Volume 1 Youtube Tagged:Body Cargo Cover Repair - PreviousCompressor Removal and InstallationNext - Cargo Cover RepairBrakes and Suspension
