Skyline Aurora pop-top opening at motorway speed fix

The Problem

The front cam latches on the Skyline Aurora pop-top were made from soft mild steel that bent easily under load, allowing one side to release and lever the opposite side open at speeds above 60 mph. Owners had tried ensuring the catches were fully engaged before each journey, but bent or metal-fatigued cams continued to fail regardless of how carefully the roof was closed.

Solution

1. With the roof closed, inspect all cam latches for any upward bend or visible deformation — a bent cam develops metal fatigue quickly and must be replaced before any motorway driving.
   • Do not bend a deformed cam back into shape to reuse it; repeated bending will cause it to break off entirely.
2. Contact Skyline directly to order the updated replacement cam latches and locking bars; Skyline supplied these free to warranty holders and sold them to out-of-warranty owners. Look up Skyline's current email address and contact form on their official website before ordering, as published contact details change over time (verify current Skyline contact details before ordering). Quote your conversion's base vehicle (make, model and year) and the Aurora roof variant so they supply the correct parts.
   • Replacement updated cam latch part number: (verify part number with Skyline before ordering).
   • Replacement updated locking bar part number: (verify part number with Skyline before ordering).
   • The improved bars have deeper cam engagement geometry that makes it significantly harder to accidentally leave a latch unsecured.
3. When fitting the new cams, apply thread locker to the cam fixing threads to prevent them working loose over time.
4. Ask Skyline about the updated front bracket, which sits visibly proud of the roofline if any cam has not engaged, making an unlatched roof obvious before driving away.
   • Updated front bracket part number: (verify part number with Skyline before ordering).
5. Periodically check the nylock nuts at the rear of the roof as they can loosen over time and cause bracket rattle or prevent the roof from lowering fully.
   • Do not overtighten; lubricate the washers every ten lifts or so.
6. If you must drive before the repair is done, fit a small ratchet strap around the closed roof fed through the cab windows as a temporary restraint only.