2005 boxster s - buzzing sound at 3k?
 

Hi Folks,
Got my S a few weeks ago now and its great fun. One quirk I noticed is that if I'm in first gear, and I ease on the throttle and take it to about 3k rpms (I'm maybe doing 20-25mph at this point) I notice a funny buzzy high pitched rattling sound, kind of like a buzz saw or something that is vibrating that isn't supposed to be.

Is this normal? Right at 3k then at 3.1k it goes away... thought maybe it was cams coming on...

Its been making this noise since new (20miles) and now it has 450 miles.

Anyone else notice this?

Thanks
Jester
silver/black s

Congrats on the Boxster!

I have not noticed the noise you described. Next time I drive it I will try to pay close attention and let youi know if I hear anything.

Is your S a 6spd or tip?


2005 Boxster S Seal Grey 6spd
———————————————————————————————————————————————–
Our other cars: 2005 SL65 Pewter / 2005 G55 Graphite / 2005 SRT-10 Viper Yellow / 2005 MazdaSpeed Miata Red / 2005 Platinum Escalade / 2005 C55 White / 2005 SSR Silver / 2004 Gallardo Yellow / 2004 NSX Black / 2002 Candy Red Prowler + 2001 Orange Prowler + 2001 Silver Prowler + 1999 Yellow Prowler / 2002 35th Anniversary Camaro SS Convertible / 1970 Camaro SS350 / 1970 Black Chevy SWB Pick up / 1969 Garnet Red Camaro SS 350 / 1969 Chevelle SS 396 / 1969 Impala SS 427 / 1968 Chevy Step Side Truck L98/700r4 / 1967 Hugger Orange Camaro 400 / 1966 GTO / 1955 Yellow Chevrolet Truck / 1934 Ford Sedan / 1930 Ford Hiboy Coupe 302 5spd

If it's pretty loud, it sounds like possibly something on your exhaust is loose or rattling against something. Right around 3k is ussually where you get the most sound and vibrations.

I can't say i've noticed this sound but the dealership should work with you on isolating it. I already had them take care of one rattle for me.

I have the same problem in my 987S. It only happens when you first drive off a exactly 3k rpm and some times going downhill. I can get it to rattle 90% of the time when the engine is cold or hot if I stop the car, shut the engine off, wait a couple minutes and startup and drive. Try that and see if you can get it to rattle and use that as your test if you take it to the dealer.

I took mine to the dealer and they gave me the run around about it being a stuck valve lifter, nothing to worry about. The only way they would look at it if it was happening on a consistant basis. I'm not worried about it, but it's very annoying coming from my first Porsche.

I have 3k miles and it is still happens once in a while. It has calmed down a bit but not completely.

Here's a link on another forum that has a similar problem. http://www.boxa.net/forum/index.php?showtopic=16897

Btw, where was yours built in? My box was made in Finland.
Look at your VIN number at the 11th digit -

'S' means Stuttgart
'U' means Finland built.

Maybe there was a bad batch.

Please post if you have any luck with the dealer on this problem.

Now my passenger window is making noise when rolled up or down. I'm going to wait until I have a couple more problems before I take it in....but I still love my Box. :)

Jester, I followed the boxa.net link above and clicked on a bunch of other threads linked in that thread. Found this:

"Porsche in Frankfurt have 'admitted' the oil relief valves are at fault - and as a result are SPECIALLY making another one fit for purpose... they are at present not at the OPC's (to my knowledge) - so don't all rush out to get one fitted..."

You may want to inquire with your service advisor if this has been checked on your car as the source of the buzzing.

I just checkout the post myself.

Didn't know they updated it.

If you read further down in the post it states possible reasons why the rattling occurs.

"I think the sound is likely cavitation, which basically occurs when a pump is pressurizing oil with air in it or theres not enough oil feed to a pump. If the relief valve is opening too early or too much in cold running (ie higher viscosity oil which = higher pressure, and also reluctance to flow into the pump) its possible the pump is being starved of oil, or being fed oil with air in it.. The air is compressed (assuming for the mo that oil is incompressible) and implodes which over time will diesel (or burn) the oil, and will reduce the oil life, increase the acidity of the oil and damage components, making matters worse...

When cavitation occurs (particularly on leading edges of pressure equipment, ie pump lobes/gears) the material in these areas is damaged causing a drop in performance and "sealing" making the matter progressively worse. This may explain why a new oil pump helped for a short while, but eventually the problem came back..."

2005 boxster s - buzzing sound
 

Just returned my 1 month old Boxster S to the dealership to get them to look at this. In my case the noise occurs at 2200rpm, only when the temperature gauge passes 60 and up to 5 mins after reaching normal operating temperature of 80.
The story from the dealership is that it is a design feature. They explain that it's an air pump that injects air into the exhaust system to meet US air quality regs. Sounds like an engineering kludge to me but no fix.

I drove the Boxster today and it does not seem to be making any of the described noises.

Mine has a build date of 04/2005 and was produced in Finland.


2005 Boxster S Seal Grey 6spd
———————————————————————————————————————————————–
Our other cars: 2005 SL65 Pewter / 2005 G55 Graphite / 2005 SRT-10 Viper Yellow / 2005 MazdaSpeed Miata Red / 2005 Platinum Escalade / 2005 C55 White / 2005 SSR Silver / 2004 Gallardo Yellow / 2004 NSX Black / 2002 Candy Red Prowler + 2001 Orange Prowler + 2001 Silver Prowler + 1999 Yellow Prowler / 2002 35th Anniversary Camaro SS Convertible / 1970 Camaro SS350 / 1970 Black Chevy SWB Pick up / 1969 Garnet Red Camaro SS 350 / 1969 Chevelle SS 396 / 1969 Impala SS 427 / 1968 Chevy Step Side Truck L98/700r4 / 1967 Hugger Orange Camaro 400 / 1966 GTO / 1955 Yellow Chevrolet Truck / 1934 Ford Sedan / 1930 Ford Hiboy Coupe 302 5spd

Steve, where on earth do you keep all those cars? You really have quite the collection.

I too live in Texas and would love to see this collection some time. You're not by chance in the Houston area are you? For some reason, I'm betting you live nearby Dallas.

Thanks MrSparkle. Glad to hear I'm not the only one. I'm not too worried about it either... mine has happened less recently but I have exactly the same "symptoms" as you. Hot or cold... right at 3k.

I just accelerate hard now past the 3k mark to make sure I don't hear it :)

I didn't go the dealer route yet... no time and I figured they would give me the run around too.

Mine has an S in the VIN. I heard most of them are built in Finland though....

Now I'm looking at my exhaust tip.... I'll have to take a pic of it... it seems a little low compared to the online pics I've seen of the S. Maybe I'm just thinking it.

My 2005 S 6speed started doing the same thing a few days ago at 550 miles.

Bill

my 05 makes a rattle noise for 2-3 seconds when driving with the engine cold, around 140 degrees... it won't do it again until the car is completely cold again.

the noise definately comes from the front of the car.

it does it every time i drive during warm up.

mine was built in stuttgart, regular box.

I took my 987S in for an early oil change and to fix the passenger's window noise the other day. Just for kicks, I had them check the rattling noise. The last dealer I took it to brushed me off. Said it was no problem. Found out today that they are going to replace the motor. It is some rare problem with something in the crankcase. They wouldn't give me the details.

I am a little relieved that they are aware of the problem but I'm not too fond of swapping out the motor. Now I have to break it in...AGAIN.

I hope they don't charge me for the oil change.

MrSparkle

Mrsparkle, G3sys, woreilly, Jester and SMC:

Please keep the forum posted on this thread and continued developments.

This is scarring the ba-jesus out of me!

Whoa! Replace the motor? And here I was just getting used to that sound...
I'm taking it in then.

I had mine in yesterday (30Sept05) out of frustration.

Of course, putting the mechanic in the car cured the noise for the moment, but he said they were aware of an issue and that there would be no engine swapping today.

I had the sense of B.S. when he said "Well, it's a sports car and some people take those noises as endearing." I told him it was endearing like a bad heat shield rattle on a honda. Then I heard about some alloy that is harder than others and that might be making the noise. My gut feeling is they know something but are on an advisory-only "put it off 'til later" response.

I was then told the positive note in bringing it in is that I am now on some "complaint list." It does not make me feel any better. This noise is really cramping my style and I'm about to boil over in frustration.

Could MrSparkle perhaps get the dealer (who did his swap) disclose the TSB? Then share with all of us here? At least we will have something to point to....

Thanks in advance!
Jess
05 Arctic Silver S

If you want to be able to access all of the TSBs for your vehicle you can go to www.alldatadiy.com and get a membership for $25/year. I would look it up for you, but mine is a 2000 so I only have TSBs up to that MY.

AllData DIY is a fantastic tool and very cheap when compared with buying factory manuals and/or not having the information you sometimes need to get the dealer to do the right thing. Go to a dealer and say "according to TSB #.... titled ...." and you have his attention.

I'm on it like a fly on a pile of ....you know the rest.

I have not received my 987 yet, so I will make sure to get the TSB info.

Mrsparkle, what did you get as a loaner car? I hope you are driving the pi$$ out of that thing!

Well, the loaner is not a porsche. I got a 02' accord which is fine. I love honda's but boy this thing is boring to drive.

I should be picking up my 987 today at lunch.

I finally got my car back after work yesterday.

Here's the info that I received:

The problem is with the design/construction of the crankcase. Under certain conditions, will rattle. It is nothing serious that will shorten engine life.

They would not disclose any more information or give me the TSB#. The service tech I spoke with informed me that he was not part of the initial conversation with Porsche. I was also told that I was "lucky". One party was for replacement and the other was against it. What a load of....

As far as the car, they neglected to fix the passenger window due to miscommunication and had to replace a leaking clutch master cylinder due to a loose pin. On top of that, they didn't bleed the clutch correctly so it feels like crap. The car feels different as well. I'm not sure if it's because of the clutch, but it does not feel "new" anymore. The engine is smooth and does not make any noises. Feels a bit slower. I'm sure I just need to break it in again.

As you can see, I'm not very happy about the situation. I feel that my car has lost it's "new" feel at 4700 miles. Does anyone know what my options are?

Mrsparkle:

I feel bad for you and your situation. You deserve much-much better.

I think you need to start making phone calls and writting letters. Start with the owner/GM of the Porsche dealer that you purchased from. Also call the 1-800-Porsche phone, and log a complaint with the proper people within Porsche of North America.

Also, very importantly, set-up a meeting with some high level person at your dealership (Service Manager and/or GM) along with the Porsche Regional/Zone Service Executive. All zones and regions have them. The dealer can find out when he/she is going to be at the dealership next.

Hope this helps.

mrsparkle:
 

Was this a type of buzzing or vibration that was located between the seats--like on the centerline of the car?

I drove a 987S a month or so ago and when driving it cold--the car only had 3 miles on it when we drove it--and giving it a little throttle (from say 1/4-1/2) the car would vibrate when I hit 3000 rpm right between the seats.

I had driven 2 other 987's and they didn't have any vibration. I have to say, had I been serious about the car (we were only trying to compare the 5 spd to the 6 spd) I'd have run from the car--it was really disconcerting.

Utter dispair. Not only is the car still rattling at 3K rpm, it is now making noise at 2100-2200 rpm.

I found the perfect place to replicate the issue. I have a mile long hill near me, fairly steep grade for Wisconsin. The noise comes about when at about 25% throttle--the uphill allows me to stay on the throttle but not gain speed. More than 25% and the noise is still there but not the resonance. Gear selection seems to show the noise more often in lower gear.

I went up and down the hill trying to convince myself the 2100 rpm rattle was somehow different and it is different. It is not nearly as loud, not nearly the resonance the 3K rpm rattle has, but it's most definitely there.

Even my wife hears it--and that's saying something.

I'm going to try to record it. For MikenOH, it is in the centerline of the car (but also hearing it out the vents), close (or below) and behind where your elbow sits on the midline arm rest. The noise could be mistaken for a sick valve train until the resonance sets in and dominates the exhaust note. It sounds like a heat shield vibrating or (perhaps better) a metal room fan that is out of balance and beginning to resonate when you turn it on high. It happens more consistant when cold, but on my hill (Hwy TT in Waukesha, WI, 1 mile south of I-94) it happens when warm, too.

I'm going to call Porsche on Monday. I don't know what to say. This is a *frustration* that will require action and not words. Mrsparkle: would you please detail more precisely what your mechanic was saying about the issue, or was that really all that was said?

just to make things clear on my post, i definately do not have the same problem as the others, mine make a funny chattering noise for 3 seconds during warmup, while driving, and the noise comes from the front of the car. it sounds like a cicada bug in the summer... again it's not from the engine, i'm not worried about it at all.

Unfortunately, I do not have any additional information.

Hopefully, I will be able to talk to the someone when they fix my window regulator. I have no problem with replacing parts in 2-3 years. I was hoping to be service free for the first 20k or 2 years. My main concern is with only 4700 miles, I already needed a new motor, clutch master cylinder and window regulator. Come to think of it, I need to have my headlights checked as well. They make a grinding noise everytime they auto level with the engine turned off.

I thought about trading up for a cayman but it shares too many parts with the boxster. What to do....

There is a thread in the UK Boxa forum that the 2100 rattle is a defective oil valve and SOME dealers there are starting to take care of it.

http://www.boxa.net/forum/index.php?showtopic=17875

2,100 RPM rattle fixed (I hope)
 

I took it to the dealer. It had a metallic rattle around 2,100-2,200 RPM between 125 and 175 degrees.

Since it only does it in this small temperature range, the techs could only try and locate it a few minutes at a time before letting the engine cool down again. After 3 days, they thought it was the oil pump, so replaced that.

Picked it up yesterday, and 4 rides from cold later, the noise is still gone. Keeping my fingers crossed!

My 06 Finland made 987S made this buzz this weekend, while cold. I'll have to isolate rpms and conditions and let you guys know. Car has 250 miles.

Sounds like a heat shield to me.

Chris C Atlanta, everytime I see this thread pop-up. I hold my breath. Kinda scarry stuff...even for Holloween! I hope it is just a heat sheild!

I too have a buzzy rattle at certain RPMs. But, it's at all temps, and it's coming from the front, like inside the dash on the right side. I've emptied the glovebox, figuring something was rattling in there, tried with cupholders open and closed. It sounds like what it would sound like if the cupholders were rattling. I'll have it checked out soon.

Well, I thought I should update everyone as I am at 5700 miles now (1000 miles on the new engine). Sadly to say, the rattling problem is something I will have to live with. I have heard the rattle 3 times on the new motor. Not bad considering I used to hear the noise almost everytime on the old motor.

Since replacing a bad clutch master cylinder, it is not as smooth as it used to be. Nothing was done at the dealer since it was "up to spec". You can't really notice it until you depress and release the clutch slowly.

mrsparkle, does California have a "lemon law"? If you do, you should try this approach with your dealer, and try to get them to replace your car. It does not sound normal or in spec to me.

I've got the rattle, too.
 

It started on my 987S at about 2K miles. I seem to get it when the engine's cold and when I decelerate down to 2200rpm.

Sorry to hear about your situation, mrsparkle. I'd check out the lemon law thing.

I wonder if some of the rattles mentioned here might be covered by this TSB:
3/05 4078 Rattling Noises From The Area Of The Front And Rear Axle

Diagnosis:
"On above-mentioned vehicles, the hexagon nut on the threaded connection for the stabilizer/connecting link can become loose on the front or rear axle due to loss of preload. This leads to rattling noises from the area of the front and/or rear stabilizer"

I saw this post on the PCA Tech website today:

"A vibration at this RPM that can be duplicated every time while parked is do to the Twin flow valve in the intake. More specifically closer to 3000 rpm's this valve is actuated and a slight vibration is felt. This is normal and is in all the non "S" models at this range.

Scott Slauson - PCA WebSite - 12/3/2005"

2200rpm rattle
 

Hi All


Have a new 2005 boxster S with about 4500 miles on it. I have the 2200rpm rattle same as many of you. Can't say that I will live with this very long. Took it into the shop today after at least 4 other tries on this. Several months ago, took a tech out and he heard it. Went back another time and he did not work there anymore. Today, I took out another tech and he heard it. I told him about this website. If anyone has sucessfully fixed this problem, please let me know. This problem occurs when the engine is cold and is warming up into the 125 range. Then it starts passing through the 2200rpm range. After warming to normal temp, this problem is not heard. I hear it behind me somewhere. This is a awesome vehicle except for this. Any help is appreciated.

Joe Alessi

I saw some talk about this on Renn Tech. Possibly Toolpants can shed some light on this.

It might be linked to an oil relief value. And there is possibly a new TSB out from Porsche.