www.smartcarofamerica.com/threads/the-development-of-the-452-roadster.163314/

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Forum thread: The Development of the 452 Roadster | Smart Car of America Forum

www.smartcarofamerica.com/threads/the-development-of-the-452-roadster.163314/ · p. 1 · Applies to: 452

Source: www.smartcarofamerica.com Topic: rain leaks, steering rack defects, motorised soft top malfunction Models discussed: 452 Language: en Solution status: no

Problem: smart Roadster 452 suffered from multiple chronic defects: rainwater leaks from roof, boot, door speakers, and front bulkhead; steering rack with fundamental interference fit flaw causing low rumbling sounds on bumpy roads; motorised soft top roof folding mechanism failure causing jamming in runners.

Solution: Warranty repairs attempted multiple times (6+ visits) including complete steering rack replacement; some owners eventually resolved leaks through persistent repairs; production discontinued due to unprofitability from high warranty claims; no permanent fix documented—some owners gave up and sold vehicles.

Key facts: - 452 Roadster was never imported to North America in significant numbers - Chronic rainwater ingress from multiple entry points (roof, boot, doors, bulkhead) affected most units - Steering rack had interference fit assembly flaw causing rumbling noises; required complete replacement under warranty - Motorised soft top roof mechanism failed to learn folding cycle correctly, causing jamming approximately 20% of the time - Poor quality control and loose-fitting parts were systemic issues - High warranty costs made each car unprofitable, leading to short production run - Fortwo cabrio roof system worked reliably by comparison - Low centre of gravity made the 452 excellent for cornering when mechanically sound - Minimal luggage space (8" boot depth) was a design limitation - Some owners eventually resolved issues and kept vehicles long-term; others lost confidence and sold