Body Cargo Cover Repair – 2.5L NA Estimated reading: 5 minutes Contributors Overview This procedure repairs the cargo cover (rear shade) on a Porsche 944 (8-valve engine) for the 1983-1985.5 and 1986-1988 variants when it fails to retract properly. Common issues include a broken coil spring or a spring detached from the retracting mechanism’s plastic end piece. Repairing the cargo cover restores functionality, keeping the cargo area tidy and concealed. Follow this guide carefully to avoid damaging the shade or components during repair. Pink and blue text represent links to additional resources, tools, parts, and partner websites. Tools Required Drill Drill bit set Punch Rivet gun Screwdriver for large screws Heat source (e.g., small torch for spring repair) Coat hanger wire (for makeshift hand crank) Parts Required Pop rivets, 999 190 103 30 Step-by-Step Procedure Step 1: Roll Up the Shade Carefully hand-roll the cargo cover shade into its assembly to prepare it for removal. Ensure the shade is evenly rolled to avoid creases or tears. Step 2: Remove the Cargo Cover Assembly Locate the two large screws securing the cargo cover assembly behind the rear seat, one on each end, approximately 25 mm (1 inch) from the edges. Use a screwdriver to remove both screws and lift the entire shade assembly out of the vehicle. Step 3: Disassemble the End Cover Place the cargo cover assembly on a large, flat surface like a table or countertop. Locate the plastic end piece cover on the passenger’s side, secured by a pop rivet. Using a drill and a suitable drill bit from your set, carefully drill out the pop rivet to remove the passenger’s side end cover. Take care not to damage the surrounding plastic during removal. Step 4: Remove the Roller and Shade With the passenger’s side end cap removed, slide the roller and shade out of the open end of the assembly. Carefully unroll the shade by hand, ensuring you do not tear or damage it. Step 5: Inspect and Remove the Shade from the Roller Examine the roller, a hollow silver metal shaft with a slot along its length and white plastic end caps pressed into both ends. Attempt to separate the shade from the roller by gently sliding the shade out of the slot. If it slides easily, set the shade aside. If the shade resists, stop to avoid tearing it and proceed to the next step. Step 6: Remove the Plastic End Cap Identify the white plastic end caps pressed into both ends of the roller, held in place by three dimples in the metal shaft. Select a drill bit matching the dimple diameter and carefully drill out the dimples on the end cap attached to the spring assembly (flat-tip end). Drill slightly into the plastic end cap if needed, but avoid excessive damage. Remove the end cap with the attached spring assembly from the roller. Step 7: Inspect the Spring Assembly Pull out the plastic end piece, central shaft, and large coil spring, which are covered by a brown paper sleeve. Remove the sleeve and set it aside for reassembly. If not already done, slide the shade out of the roller’s slot. Inspect the spring and plastic end piece. Check if the spring’s end has detached from the plastic end piece or if the spring is broken, as these are common failure points. Step 8: Repair the Spring If the spring’s end is broken, heat approximately 3 mm (1/8 inch) of the spring’s end using a small torch, then bend it into an “L” shape to fit into the plastic end piece. Allow it to cool before proceeding. If the spring is detached but not broken, reattach it securely to the plastic end piece as originally designed. Step 9: Reassemble the Roller Slide the shade back into the roller’s slot, ensuring it is aligned and secure. Reinsert the spring assembly, shaft, and plastic end piece into the roller, covering it with the brown paper sleeve. Re-dimple the metal shaft next to the drilled-out dimples using a punch to secure the end cap. Ensure the cap is firmly in place. Step 10: Rewind the Spring Before placing the roller back into the assembly, rewind the spring inside the roller by approximately 10-15 revolutions to restore tension. Create a makeshift hand crank from a piece of coat hanger wire to assist with winding, as winding by hand may be difficult. Step 11: Reinstall the Roller and End Cover Slide the roller and shade back into the cargo cover assembly through the open end. Secure the passenger’s side plastic end cover using a new pop rivet, 999 190 103 30, and a rivet gun. Step 12: Reinstall the Cargo Cover Assembly Place the cargo cover assembly back behind the rear seat. Secure it with the two large screws, one on each end, approximately 25 mm (1 inch) from the edges, using a screwdriver. Post Procedure Checklist Test the cargo cover by extending and retracting it to ensure smooth operation. Check that the shade retracts fully without jamming or tearing. Verify the assembly is securely mounted with no loose screws. Inspect the shade for any tears or damage that may have occurred during repair. Sources Clark’s Garage Pelican Parts Porsche 944 Workshop Manual, Volume 1 Youtube Tagged:Body Cargo Cover Repair – 2.5L NA - PreviousBumper Cover Removal – 2.5L NANext - Cargo Cover Repair – 2.5L NAClock and Temperature Controls Removal and Replacement – 2.5L NA
