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Please don't take this as a personal affront but it sounds like operator error to me.
May I make a few suggestions?
One, I know the manual says not to exceed 4K rpm until warm, but to me that is still too fast when all the bits inside are cold and not at their proper size. Remember there are steel, aluminum, etc. parts in there and each expands at a different rate and all are designed to be operated at a specific temperature. And at that temperature is when all are at the proper size.
So if it were me (and I do this), I would cool it, so to speak, on the 4K rpm bit at first. Instead, consider 2K rpm until the temp needle is well up into the operating range. Gradually increase the engine speed over the next few miles.
The oil is both warmed and cooled by the heat exchanger on the engine and its temperature will lag behind that of the coolant. Give it time to heat up as well.
Remember too, it isn't just the engine you are warming up here. You have a transmission and differential, too.
Secondly, it sounds (as was suggested earlier) as though you are not properly matching the throttle let-off with the declutching process and perhaps engaging the clutch too rapidly afterwards. Not many folks out there anymore understand from a mechanical point of view what happens during this process. If you have never worked on or even looked at the mechanical bits that are involved here, it's hard to understand.
So my suggestion here is to find someone who really knows how to shift smoothly and let them drive your car from cold. If they don't have a problem...
That's why I remain amazed at the wannbe drag racers out there in Boxsterland. Boys and girls, these are not drag cars and you are putting a lot of stress on them by doing the 0-60 thang that they just are not designed to do. Can they do it? Sure. Are they at their finest doing that? No. That's what curvy roads are for. Few cars can touch a well driven Boxster in its element.
Anyway, if you are indeed doing the shifting properly and there is a mechanical problem, I would look for a reason for the clutch to disengage too slowly. And it sounds like your shop has done that by looking at the throwout (release) bearing (and hopefully the related operating components like the master/slave cylinder, etc.).
I hope this helps.
All the best,
- Mark
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