I am posting this in hopes that someone has experienced this problem and can give me some more information that would help me at the dealership to get this addressed correctly. The dealership is very friendly, but they just don’t seem to know a lot about these cars. My service writer even went as far as to say that the mechanics dislike having these cars in for service to the top because it is so hard to work on. (I think her exact words were that they groan every time they see one).

I am having a problem with nicks showing up on the top of my 2003. At 800 miles I had the rubber trim piece around the rear driver side quarter window because it got torn. I asked the dealership to check the top, and they said everything was fine and that it was probably just delivered that way and I didn’t catch it or I torn it while washing it.

2,000 miles later, the trim piece is nicked again – in the same exact spot – here is a picture to help:

http://members.***.net/5337/top1.jpg (far)

http://members.***.net/5337/top3.jpg (close)

Around that time I also noticed a chunk missing from my passenger side roof. Luckily I had some touch up and it really isn’t noticeable.

http://members.***.net/5337/top5.jpg (far - to give perspective)

http://members.***.net/5337/top2.jpg (close)

I also noticed that on the driver side, in exactly the same place as the passenger side got nicked, there is a minor abrasion on the driver’s side upper window molding:

http://members.***.net/5337/top4.jpg (close)

I’ve watched the top go up and down and the only thing that comes close to the quarter window molding are the two retractable wires that go to the deck lid – and I don’t see how those wires could have torn that rubber.

 

I'd check what happens as the top goes into the trunk, particularly as the sides pass the hinges as it transitions to/from the trunk. I'd also inspect the space in the trunk for any protrusions.

Considering it's on both sides, I'd check the hinges for any signs of previous contact. I intend to double-check my top for any marks as well. I'll let you know if I find anything.

I had to have the rear decklid hinge striker adjusted over a year ago because the trunk would slide sideways ever so slightly and click into place as it came back down from transitioning the top.
( See https://www.clublexus.com/forums/sho...ighlight=hinge )

 

Oh man, sorry for your troubles. There's something obviously wrong with your top. I just checked my car and it's perfect, but only have 1,200 miles and have opened the roof probably 5 times.
I'm still waiting for a darn service manual to be available for my '04 to learn more about the top.
I really want to know how the roof works. What do the cables do? Are they in tension open or closed? Are the latches in front cable-actuated with 1 motor, or does each one have its own motor? This is a common source of problems in BMWs. If somebody has a brief technical explanation (how many electro-hydraulic motors, cables, etc) how the top mechanism works, it'd be appreciated. I'm particularly interested on the job of the cables, and where they're attached, since a couple of owners had 'loose' cables. Would like to check them out myself. Can I safely stop the roof at any point to scrutinize the system?
Thanks.

 

I don't know "how" the top works, but I do know that you can safely stop the top, but if you stop it at a position too far from midway, the weight of the top will slowly lower it into the trunk or back onto the windshield, depending on where you stopped it.

For cleaning the back window or putting some 303 onto the gaskets, I have often stopped the top when the rear window is perpendicular to the ground. It will stay in this position indefinately, and allow you access to clean or inspect almost all of the areas involved. Leave the engine running, just as a safety precaution; it's generally a bad idea to operate the top at any time without running the engine.

This is the only practical way to clean the inside of the rear window.

It's also a good photo op.