Quality control ain't what it used to be

[AFJuvat]

As some of you may know, I am a mechanic in a small independant Porsche only garage.

The other day, a 2002 996 with the Aero Kit option comes in for its annual service.

Annual service entails changing oil, top off fluids, inspect brakes, checking filters etc. The car had just over 6000 miles on it.

Oil filter housing had a few small pieces of metal in it when I removed it - not completely unusual as it is a very low mileage engine and this is its first oil change.

Car is filled with Mobil 1 15W-50.

I complete the service, torque down the oil drain plug and the oil filter housing down per the book.

Owner picks up car, and takes it home - 40 minutes later, he calls up saying the engine started knocking like crazy and the car dumped a bunch of oil on the ground.

Car is towed back to the shop, drain the oil - car lost half of its oil volume (about 5 quarts) and the oil that is left is loaded with metal bits.

Oil filter housing is the same.

Evidence of oil leaks between engine and transmission

Diagnosis: Real main seal failure, resulting in total engine failure.

Per conversation with the dealer, the rear main seals "let go if you look at them funny" and that "we never replaced engines under warrenty with the older 911's, but with the 996, we are replacing 2 or 3 per month."

So as an early Xmas present, the poor owner gets a new engine for his car that only had 6k miles on it.

So, for those of you that own, or are thinking of buying a 996, watch it for oil leaks sprining up out of nowhere or clunking noises like a hawk.

Quality control at Zuffenhausen just ain't what it used to be.

AFJuvat

[Paul Thomas]

People were probably saying the same thing from 74-77. Quality has gone to hell. They will work through it. At least they are fixing it. I had a new Honda that had a rear main seal replaced under warrenty and then later when the same type of problem resurfaced they denied ever doing it.

Paul

[Bob's Flat-Six]

It sounds like the seal may have push out completely to loose that much oil so quick ?
What a hassel to have a new car go in for a motor. I think I would go for an extended warranty on that model.
Interesting info, Thank's

[Crachian]

I've always wondered . . .

So what happens now? Must the owner go to the dealer for the new engine, or can your independent shop perform the work and seek reimbursement from Porsche?

[pwd72s]

I've posted this before, but perhaps it bears repeating? In the Oct. 1973 Issue, PORSCHE PANORAMA, Betty Jo Turner published her "conversation" with Ferry Porsche.
BJT: "But is there a limit to the size of the engine the 911 design can accept?"
Ferry Porsche: "It is more a limit for an engine in the rear than for an engine that is air cooled. Now, to put a water-cooled engine in the rear and to have a radiator in the front, that's not very intelligent."

It's too bad that Ferry is no longer around to run things...Today? Nothing Porsche makes new would interest me...even at the GT1 level, if I'd won a lottery, I'd buy Ferrari... It hurts me to say this. I joined PCA in '67, my first P-car was a '66 912. I'll continue to hang on to my '72S. But...nothing new that Porsche produces today truly excites me. Today's Porsches? They only want to be like other "designer label" products. So, tell me...just what is the hot desiger label ? Is Jordashe still in? Maybe we should all jump on it...in order to be "kewel"?

[s_wilwerding]

The rear main seal is a common fault on both the Boxster and 996 (since they're basically the same engine). One guy on Porsche Pete's Boxster board has gone through, I believe, four RMSs on two different engines. Supposedly, the RMSs available now (and on 2003 cars) solve the problem.

Time will tell.

[beepbeep]

My understanding is that this problem only happends to 996's and Boxters with el-cheapo wet sump (one they made to save money).

GT3, GT2 and Turbos are immune to this...