AHHH..The top track broke on sliding door, Help

[mnm99]

I think I can help you with this. I've had my hatch door out several times and I completed this exact repair in 2016. I obtained parts from BoatOutfitters.com. My door tended to sag like yours does, so I added a third truck to the bottom track and to the top track (in in the center of the door, between the existing tracks) to help keep the door from sagging in the heat. Replace all your trucks while you're at it.

You will need the following from BoatOutfitters: (1) Boat sliding door upper track SKU 148-1164-53, length, 53". (3) Boat Sliding Door Truck B, .975" tall, SKU 016-1038 (This is for the upper track). (3) Boat Sliding Door Track A, .885" tall, SKU 016-1037 (This is for the lower track).

You've already figured out how to access the upper track by removing your instrument panel. I think I also moved my compass so I could get another hand in there.

To get the hatch out, unscrew the lower truck from the hatch. Once you get the screws out, it comes out pretty easily.
Accessing the old screws in the upper track is tricky. Of course, I had one stubborn screw that gave me problems. As I recall, I used a stubby screwdriver to get in there.

The best thing I did was adding the third truck to the top and bottom of the door. To install that third truck, use a countersink bit so the screw heads sit flush with the door, just as the original equipment trucks were installed. Measure twice and drill once, lol.

Good luck, you can do this!
Tim

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That was a big help thanks. Did you replace the lower track also? I think i'm going to do both in aluminum.

 

[JustRight]

I only replaced the upper track. I used plastic, and I did so with a certain hestitation initially. Now that it’s been in a couple of years, I’m glad I did it with parts essentially the same as OEM. I wonder how the plastic trucks will interact with the aluminum track? I did notice that the original lower track trucks were worn badly and just about ready to fail by the time I replaced them. I will say that the plastic track was flexible, so it made it easy to install the track without concern that you mentioned previously about getting the track into the tight upper space. I think the proper adjustment of the trucks on the door can play into the degree of stress exerted on the track. I had to play around with the adjustment of the trucks a little to make the door close smoothly and land properly on the latch mechanism.

 

[JustRight]

The more I think about it, I had to mess with the upper track adjustment slightly as well. When I first installed the upper track, I installed the plastic track dead straight, using a straight edge for reference. But the door wouldn’t close properly. Eventually, I ended up with a very slight curve in the upper track (curved ever so slightly aft as the hatch closes, if I recall correctly) to make the hatch land properly on the latch. Maybe that’s why Sea Ray used plastic...to increase flexibility, or fend off the effects of salt water. I don’t know....

 

[mnm99]

The more I think about it, I had to mess with the upper track adjustment slightly as well. When I first installed the upper track, I installed the plastic track dead straight, using a straight edge for reference. But the door wouldn’t close properly. Eventually, I ended up with a very slight curve in the upper track (curved ever so slightly aft as the hatch closes, if I recall correctly) to make the hatch land properly on the latch. Maybe that’s why Sea Ray used plastic...to increase flexibility, or fend off the effects of salt water. I don’t know....

I'll take a look. I think the 2006ish and up have Aluminum. From what I'm told at least. If this is true, maybe it's because of breakage problems. Who knows..

 

[Mischief Managed]

I know this thread is a bit old but I’m about to replace the hardware and add the 3rd truck to my 320 cabin door. I was wondering if that extra 2 trucks is still working for you and if there is any friction with the sagging door? Thanks a million.

 

[JustRight]

I know this thread is a bit old but I’m about to replace the hardware and add the 3rd truck to my 320 cabin door. I was wondering if that extra 2 trucks is still working for you and if there is any friction with the sagging door? Thanks a million.

It’s still working. I don’t regret adding the two trucks at all. When it’s particularly cold in the Spring or Fall, I notice the door is harder to open and close - but I don’t think that friction is caused by the additional two trucks, I think it’s caused by the influence of the cold on all of the plastic parts including the door itself. When it’s warm outside (60 to 90 degrees or so) the door works smoothly.