2004 Boxter S Intermediate Shaft Failure
Discussion
Hi I'm new to the forum but come with a slightly heavy heart!
I've just had my car towed away this week and the dealership informs me my Intermediate Shaft has failed and they will be replacing the engine after only 12000 miles.
Is there any history of this?
At the moment its still under warrenty so Porsche will cover the cost but it concerns me for the future! This is my first Porsche and I had had great expectations of reliability etc
I've just had my car towed away this week and the dealership informs me my Intermediate Shaft has failed and they will be replacing the engine after only 12000 miles.
Is there any history of this?
At the moment its still under warrenty so Porsche will cover the cost but it concerns me for the future! This is my first Porsche and I had had great expectations of reliability etc
Sorry to hear the news. Not heard of this failure before...rear main seal yes, cylinder liners yes.....new one on me. Dont be put off sounds like very bad luck to me. Covered under the warranty so the new engine will have the same engine number as shown on the Reg Docs. I had one replaced before on an early 2.5 and thats what they did so no-one will know unless you/dealership inform them and I dont think Porsche advertise such failures too much. Keep ya chin up 
The intermediate shaft is the shaft between the gearbox and engine, although I'm not sure I imagine all engine models have them. In fact it was the bearing that had failed which I found out from the PCA (Porsche club America) website that seems to occur only on later models that have a single rather than double roller bearing on this shaft.
I've just received the car back last week with a replacement engine, but no extended warranty. I had to haggle with the Porsche customer services for them to contribute something towards an extended warranty next year which they did in the end.
I've just received the car back last week with a replacement engine, but no extended warranty. I had to haggle with the Porsche customer services for them to contribute something towards an extended warranty next year which they did in the end.
Unfortunately, I've also had this problem. My 99 Boxster with only 12,700 miles had an intermediate shaft failure earlier this month. Of course, that's only what they believe is the issue since they never actually tear down the engine for this - only replace it. Fortunately, the dealer I bought the car from covered the expense (12k-13k) even though I have no warranty.
I believe this is a fairly common problem and is not limited to newer years. On another website I found over 20 people (16 with '97-'99) who had this same failure. Most were low milage (3k to 25k) with some as high as 65k. The service manager at another Porsche dealer told me he sees this quite often in the '97-'99 range.
In most cases the vehicles mentioned above were out of warranty. Nearly all had their engine replaced with an out-of-pocket expense of around $2,000 - $3,000 (generally after getting Porsche of America involved - or switching dealers).
What is interesting to me is that my dealer was able to state that it was "probably the intermediate shaft" even though he has no way of knowing unless he tore the engine down (his words - not mine). Since they always suggest replacing the engine for catastrophic failures - how would he know?
I strongly believe this is a know assembly defect (mis-alignment) of the intermediate shaft affecting some Boxsters. Naturally, it's just too expensive to replace every engine so they wait for the failures. Initially, they refuse to pay - but generally agree in the end. Essentially, this is a slow recall. At least, this is what my research is showing.
For this reason, I would not pay a dime to replace any Boxster engine purported to have this problem - in warranty or out. A known manufacturing defect that prevents normal & expected use of a product violates the Implied Warranty of Merchantability and Fitness of Purpose. Simply stated, my Boxster was slated to have this problem the minute it rolled off the floor. It might fail at 3k, 13k, or 60k - but it was going to fail. As such, there was no way for it to fulfill its stated purpose - being driven. This is one warranty that doesn't expire!
Stick up for your self if you have this problem!
Sorry for the long reply - But NO ENGINE SHOULD FAIL UNDER 20K MILES - particularly a Porsche.
Peace.
I believe this is a fairly common problem and is not limited to newer years. On another website I found over 20 people (16 with '97-'99) who had this same failure. Most were low milage (3k to 25k) with some as high as 65k. The service manager at another Porsche dealer told me he sees this quite often in the '97-'99 range.
In most cases the vehicles mentioned above were out of warranty. Nearly all had their engine replaced with an out-of-pocket expense of around $2,000 - $3,000 (generally after getting Porsche of America involved - or switching dealers).
What is interesting to me is that my dealer was able to state that it was "probably the intermediate shaft" even though he has no way of knowing unless he tore the engine down (his words - not mine). Since they always suggest replacing the engine for catastrophic failures - how would he know?
I strongly believe this is a know assembly defect (mis-alignment) of the intermediate shaft affecting some Boxsters. Naturally, it's just too expensive to replace every engine so they wait for the failures. Initially, they refuse to pay - but generally agree in the end. Essentially, this is a slow recall. At least, this is what my research is showing.
For this reason, I would not pay a dime to replace any Boxster engine purported to have this problem - in warranty or out. A known manufacturing defect that prevents normal & expected use of a product violates the Implied Warranty of Merchantability and Fitness of Purpose. Simply stated, my Boxster was slated to have this problem the minute it rolled off the floor. It might fail at 3k, 13k, or 60k - but it was going to fail. As such, there was no way for it to fulfill its stated purpose - being driven. This is one warranty that doesn't expire!
Stick up for your self if you have this problem!
Sorry for the long reply - But NO ENGINE SHOULD FAIL UNDER 20K MILES - particularly a Porsche.
Peace.
There is a flange on the end of the shaft. The threaded end of the intermediate shaft pokes out in the middle of the flange. There is a bolt on the threaded end. When the transmission is removed you can see the flange. If the threaded end has broken off the shaft you know the shaft is not happy.
Count us in. We just got word that our second RMS failure included the intermediate shaft. The dealer handling the repair is taking care of everything. The car will be layed up for about 2 weeks while the paperwork clears and a new lump is shipped from Germany. Ours failed at 17,000 miles.
Oh - it's an '04 S.
Oh - it's an '04 S.
I own a 2004 911 C4S which just experienced an intermediate shaft failure yesterday. The car has 24k miles. I hear what sounds like metal banging around in my muffler, and then the car just dies and won't start again. I call the 800-PORSCHE (Porsche Roadside Assistance), and after giving them my address, the car's VIN, my name, and a description of the problem, they send out a flatbed tow truck free of charge. This morning I hear back from the dealership. The intermediate shaft failure caused a lot of damage. They are replacing a number of things under warrantee, including the engine. The dealership is providing me with a free rental car (Subaru Legacy), they are out of loaners. I'm told they will expedite delivery of the new engine and everything else; I should be able to pick up my car in 3 days.
This is Porsche #4 for me, and this is the first time anything major has gone wrong with it. As long as this is handled properly, I'll continue to be loyal. Stuff happens. =)
This is Porsche #4 for me, and this is the first time anything major has gone wrong with it. As long as this is handled properly, I'll continue to be loyal. Stuff happens. =)
Just a quick update, after expediting replacement parts out to the dealership from California and Germany, it took only 4 days to get my car back. Considering all the work that it looks like they did, I'm impressed with how they dealt with the situation. Thank you Porsche! I look forward to buying my next car from you also.
Bought my first Porsche in late August, 2002 pre facelift Boxster S Tiptronic. Low mileage, 2350 recorded miles, FSH. 1 month later, rattles from engine which sounded like a stone in the belt cover, 5 miles later, no oil pressure.
Intermediate shaft failure ! (This shaft drives the oil pump and other ancillaries, but is not the shaft between engine and gearbox.)
Currently awaiting its return with a new engine. Thank goodness for the warranty!
Not exactly impressed with Porsche reliability having driven over 600,000 miles and never had an engine fail in service before.
Intermediate shaft failure ! (This shaft drives the oil pump and other ancillaries, but is not the shaft between engine and gearbox.)
Currently awaiting its return with a new engine. Thank goodness for the warranty!
Not exactly impressed with Porsche reliability having driven over 600,000 miles and never had an engine fail in service before.
my car had the same thing at 7000 miles, it does seem to happen quite quickly (as far as I have seen) so if it does not happen (fail that is) in the next year the its probably gonna be alright for ever.
The thing I really thought was crap is that the new engine that I got was not warrantied for any longer than the original car warranty which I thought was crap.
but then a 2 year warranty is rubbish anyway.
>> Edited by themaskedavenger on Sunday 9th October 09:36
The thing I really thought was crap is that the new engine that I got was not warrantied for any longer than the original car warranty which I thought was crap.
but then a 2 year warranty is rubbish anyway.
>> Edited by themaskedavenger on Sunday 9th October 09:36
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