Rear main seal

[98Boxster98]

Originally Posted by MNBoxster

To me, it's unconscionable that a company with the reputation Porsche has gained would go nearly a decade without fixing the issue. Instead they have chosen to take the Risk Management approach and apply Band-Aids on a Case-by-Case basis. Words cannot describe my disappointment with this situation.

Don't get me wrong, I love my Boxster. But this single perrenial flaw would prevent me from Wholeheartedly recommending it to anyone, especially if buying a previously owned Boxster. There are just too many other Great Cars out there to be buying into these kinds of troubles. I'm not even certain I would do it again... and I have a good RMS (Knock on Wood)...

Happy Motoring!... Jim'99

Very well stated. I have the same mixed feelings and opinions on the ownership of my Boxster.

[wild1poet2]

thanks for the info..... you would think center boring or altering the casting process would be straightforward.

Let's hope the Cayenne RMS works.

[wild1poet2]

Just another thought. If this problem is of widespread and re-occurring nature I am also surprised there has not been some type of class action by owners to have Porsche extend warranty coverage on this repair.

This would explain the reports of some owners being accomodated with covered repairs and even new engines while others not(ie; complain vociferously and they'll concede to make you go away).

I've read that this is an engineering defect which would seem to be in violation of implied merchantability codes(caveat: I'm not an attorney).

Presumably this problem will continue over to the Cayman.

Anyone know what percent of the Boxster engines experience this problem? I've read its as high as 100%. This must be an exagerated estimate. I hope.

yup, my 02 boxster just had the rear seal leak right before the warranty ended this past november 05...thank god.....but i don't like what i have read here about it happening again...kar only has 15miles....i'm so not forking out any money on another leak if it happens out of warranty...im screamin n yellin

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[MNBoxster]

Originally Posted by wild1poet2

thanks for the info..... you would think center boring or altering the casting process would be straightforward.

Let's hope the Cayenne RMS works.

Hi,

Well, it just isn't as straightforward as you may think. In traditional Casting, where post-cast Machining is performed, the Mold allows for the excess material which the Machining subsequently takes away.

Porsche's method (adopted from Audi), does not allow for this excess material, so simply machining the Block halves to provide for the Center-Boring won't work. They'd be looking at redesigning the molds and possibly the Block halves themselves to provide additional support where the Boring takes place. The metallurgy may even require some tweeking. This would be extremely costly and possibly unrecoverable from the Price Point and anticipated Unit Sales the Marketing Dept. has set for these Cars. Remember, this Market Niche is already overcrowded as it is with more new Two-Seat Drop Tops still being introduced. Unofficial Surveys (Porsche won't release any stats on RMS Failures) have pointed to about 20%-25% of all cars being affected. But, releasing this kind of info in an already overcrowded Market could kill the Model completely.

Block Casting is a very difficult thing. Years back GM, (the Buick Div. actually), decided to make an all-alloy 265 C.I.D. Smallblock V8. Their first attempts yielded a reject rate of more than 99% (less than 1 Block out of 100 Cast was usable). After 5 years, they managed to reduce the reject rate to 85%, yielding 15 usable Blocks for every 100 Cast. This was so potentially unprofitable that they sold the rights of the Engine to Rover, who reformulated the Metallurgy and re-engineered the Casting Process to achieve a reject rate of only 9%, producing 91 usable Blocks for every 100 Cast, and the venerable Rover V8 was born.

Also, if Porsche did reinvent the M96/M97 Block, it would be akin to admitting fault in the earlier design which could have recall cost implications (given the near 500,000 986/987 and 996/997 Cars sold) that would jeopardize the financial strength of the Company, something unlikely to be accepted by the Boardroom in Stuttgart.

No, despite all the Boxster's excellent qualities... and there are many of them, I can't help thinking that deep down there beats the Heart of a Lemon. Good Company PR, Past Reputation, and Near Fanatic Fan Loyalty (some of which I assume will speak in opposition here) have done much to disguise the fact...

Happy Motoring!... Jim'99

[wild1poet2]

Thanks MNBoxer for an excellent analysis. Gee, the 20 to 25% event rate actually sounds better than I was expecting from all the posts. I have to assume that they tested the prototypes and ran durability runs. The RMS on the prototypes must not have failed. Then they went into production and the flaw occurred there in the production process.

This problem must not be harming the PR and Marketing of the cars.

[Brucelee]

Too bad Dr. Deming is no longer with us. Porsche could use his talents.

[dklumb]

Thanks guys for all the feedback. I am taking my Boxster in tomorrow for the seal repair. I understand that they will use a go / no-go guage to determine how off center the cases are. This shop claims they use some epoxy mixture to help the cause. I will let you know how it goes.

[Crashcup]

Hey, I've got you all beat. I have a 2003 Boxster S. At 18,926 miles I had the oil filler tube hose replaced, the rear main seal and the intermediate shaft seal. That didn't stop the oil leaks. Now at 20,000, it's been in the shop a week to have all the seals around the spark plugs replaced. I've got a 330i BMW with 50,000 that hasn't leaked a drop of anything. I only have around 18 months left on the Boxster warranty so I guess I better start saving seal replacement. It's disappointing to hear that I have to replace it about every other tire change. I'd get rid of it if it wasn't a gift. Never look a RMS in the mouth, you know...