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Old 10-09-2005, 02:50 PM   #1
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Common Ailments

I purchased my black 2002 Boxster S 2 months ago with about 28K miles on it and have been going thru it fixing all the small (and thank God they are small) problems since. Although one can find hundreds of posts on this forum depicting Boxster problems and solutions, I thought it might be good to start one thread where we can all concisely post all the items we have had to repair on our cars, in an effort to share the experience with others. Many thanks to all of you who answered my questions about the car in he past.

My fixes were as follows:

#1 Cracked coolant bottle

Symptoms: Flashing red light on dash indicating low coolant as well as little or no coolant tin the bottle. Engine coolant temp stayed within tolerance, but could have easily gone high if this problem had gone unattended. Even when topped off level would noticeably drop in a few days.

#2 - Rear plastic window was separating from the canvas top.

Fix: Had the dealer install a whole new window. Looks much better and won't leak. I tried to push for a whole new top but they would not budge. I have read posts from other members who have had the entire top replaced under warrantee.

Finished it off with Ragtop cleaner and protectant.

Top looks very good with the exception of the pressure marks and scuffs.

#3 Car needed 30K maintenance.

Fix: I replaced the pollen and air filters myself. I got stupid and had the dealer do the oil change, spark plugs (not required at 30K on a 2002 S but I did it anyway) and flushed the brake fluid. Due to the insane price he charged me for this service I will be doing all the maintenance I can possibly do in the future myself.

#4 "Titanium colored inner windshield trim (this is only "titanium" from 2000 on Boxster S only) was discolored. Looked like it was rusting.

Symptoms: Very obvious when looking closely at the car.

Fix: Had the dealer replace it under warrantee. Got a new windshield out of the deal as well, as they often break when removed. Had to take it back to get the outer rubber seal "refitted" ( glued down with a urethane glue) as it did not fit flush on the first pass above the top corners. Looks good now. Interesting to note the first dealer said this was not covered under warrantee. Took it to dealer #2 and they took care of it.

#5 Paint had small scratches everywhere. (curse of the black car)

Symptoms: Looked at the car under direct sunlight. You could see hundreds of hairline scratches on every body panel, resulting in big ugly spider webs.

Fix: I have spent more time on this problem than anything elese. I purchased a Portacable Orbital Buffer with an assortment of Lake Country foam pads, medium and light cut polishing compound, Klasse All in One and Klasse Sealant Glaze and a bunch of cotton diapers. Many, many passes later it looks very good. I have been looking at every black car I see parked to compare and most of them look much, much worse than mine so I am going to learn to live with the relatively small number of defects that are not going to come out. Think long and hard before you buy a black one.

#6 Former owner delivered the car with a really cherry ding in the left front fender.

Symptoms: Obvious to the most casual observer

Fix: Fortunately I have a friend who owns a body shop who professionally repaired the ding and re-sprayed the entire fender. Looks so good I do not think anyone could tell it was repaired. They are in the LA area and I will be happy to recommend them if anyone is interested.

#7 Former owner scratched all four Techart wheels.

Fix: This is the last thing I need to do. I will be dropping of the wheels and tires at a place called Wheels America in Santa Fe Springs CA next week to have them completely refinished.

#8 Former owner took the roll bar inserts prior to delivery.

Fix: Purchased a set used from a fellow forum member for $125.00

#9 Former owner took the Porsche Crest wheel center caps.

Fix: Bought a set on ebay for $65.00 - Got lucky and they are brand new - look great

#10 Radio would seize up intermittently.

Fix: Removed the after market ipod docking station. Found the interconnecting cable had wrapped around the pulley for the throttle cable (neat). Once removed it has not seized since.

#11 Car needed brake pads:

Fix: Bought OEM pads from the dealer and installed them myself. Really was not that difficult. Hardest part is removing and replacing the brake pad wear sensors without cracking them.

#12 Floor Mats were worn out especially on the drivers side.

Fix: Bought new ones form the dealer and installed myself.

#13 Former owner had wiped out the 3 different plastic air dams fitted under the front of the car.

Fix: Fortunately they were small ones. Bought new at the dealer and replaced myself

All of this stuff was basically TLC. I know I will have more maintenance and a clutch job coming up, but other than that I am going to enjoy this thing by driving it instead of working on it.

Thanks again to all who provided advice on getting all of the above finished.

Hope we donít see too many horror stories posted here, but, it is what it is and I think this type of information will be very good to share.

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Old 10-09-2005, 05:13 PM   #2
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Location: auburn, al
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Hey this is a great idea. Since I bought my car I have done much and have many pending projects:

1) Oil change as soon as I got home. No record w/ the car to reflect when the last one had been performed.

2) New cross drilled rotors and mintex pad all the way around, went ahead and got new sensors for all four wheels also(wasnt sure which were indicating brake wear. Also got a power bleeder and ATE supe blue brake fluid. Brakes are very responsive compared to the worn pads and rotors.

3) 60K service. Even though car only has 52K miles. Just wasnt sure about the upkeep for car and just seemed like good insurance. Plugs, air filter, charcoal filter, serpentine belt, fuel filter. Everything was really easy to do. I took my time and it only took about 2hrs. Took a picture of belt routing to ensure proper direction.

4) Removed all lug bolts and brushed w/ brass brush sprayed w/ primer and hammered metal krylon paint. Looks so much better.

Bought all my parts from PAP-Parts I recomend them highly. I only intended to buy the "tune-up" parts from them, but told them I was interested in doing brakes and rotors also. The salesman convinced me to shop around and find the best legitimate price for the proper parts, then call back and he'd beat it. Saved me nearly $100 for all rotors, pads, sensors. Not to mention the savings from combined shipping. Call and talk to them about parts 1-800-944-2964.

I have many more projects to get to but have to save a bit more. They are getting more expensive as I go
-need new top, interested in glass option but really wanna see how well they hold up over time
-getting a complete paint job, clear coat has peeled off on hood and price for respray was nearly half the price of full paint. I also have many small dings and scratches that really aggrevate me to death. They are going to be repaired while its in paint shop
-want to upgrade speakers and head unit.
Much more to do but this is a good start.
1999 Arctic Silver Metallic/Graphite Grey top/ tiptronic transmission
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Old 10-09-2005, 06:21 PM   #3
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Location: Minneapolis/St. Paul, Minnesota, USA
Posts: 3,308

You state: "-need new top, interested in glass option but really wanna see how well they hold up over time..."


If you need a new Top, go ahead and do this with the Glass Rear Window. The GMHH (?) may have had a teething problem or two, but they are pretty much sorted now. It's far better than investing in another Plastic Window Top. The Fabric is identical, it's just the Window which differs significantly. Hope this helps...

Happy Motoring!...Jim'99
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Old 10-10-2005, 09:18 AM   #4
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Awesome idea for a thread!

Originally Posted by Mr. Boone
#8 Former owner took the roll bar inserts prior to delivery.

Fix: Purchased a set used from a fellow forum member for $125.00
Did you leave the part out where you "beat the PO into oblivion for being such a jerk"?
Originally Posted by Mr. Boone
#11 Car needed brake pads:

Fix: Bought OEM pads from the dealer and installed them myself. Really was not that difficult. Hardest part is removing and replacing the brake pad wear sensors without cracking them.
FYI: It's good to just go ahead and replace the brake pad wear sensors when you do the pads. They get pretty hot under normal use so the wire covers and/or sensor clips can crack over a long period of time giving you a false brake pad warning. I've found it easier to just go ahead and do it WYAIT rather than have to do it later.

We bought the 2000 Boxster in June, 2003 with 21K miles on it. So far our fixes have been:

1) O2 sensor at 25K (warranty)
2) 30K Service at dealer. (Plugs, Cabin/Air/Oil Filters & Oil, Top Lube, Hose Checks) and program the doors to automatically lock at 5mph - $850.
3) Brake pads DIY all four wheels at 30K. $130
3) 45K Oil Change & inspection at P-car specialist. $200
4) 60K Service DIY. (Plugs, Cabin/Air/Fuel/Oil Filters & Oil, Replace Drive Belt, Top Lube, Hose Checks) $200 (compare to dealer above even w/ add. services )
5) Brake Pads/Rotors DIY all four wheels at 60K. Used Mintek Red Box (low dust) pads and Zimmerman OEM rotors plus fluid change. $450
6) Replace engine compartment temp sensor DIY at 62K. $30
7) Coolant reservoir replacement DIY at 62K. (Replaced reservoir, hoses from reservoir, clamps & coolant) $300
8) Replace engine idler rollers DIY at 62K. $150
9) Replace oil separator DIY at 66K. $100
10) Replacing front right radiator fan DIY at 68K. (planning to take the bearings out of the old one and see if they are replaceable) $150
1987 928S4 Silver Metallic (980)/Navy (TP) 5-Speed
2000 Boxster Speed Yellow/Black 5-Speed
1966 Wife White/Brown Top
1986 Daughter White/Brown Top (Sold!)
1992 Daughter White/Blonde Top
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Old 10-11-2005, 03:40 PM   #5
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[QUOTE=deliriousga]Awesome idea for a thread!

Did you leave the part out where you "beat the PO into oblivion for being such a jerk"?

I was flabbergasted to find that people will even do stuff like that. Former owner was by far one of the biggest jerks I have ever met in my life. It was all I could do not to retaliate, but after allot of deliberation I decided it was not worth my time. It is one thing to take things off the car before you present and sell it. It is another thing to take things off the car after you sold it and before you deliver it. Had it not been for the CPO warrantee and the fact that I am reasonably sure the car is quite sound mechanically - knock on wood - I would have found another car to buy. I think there is a reason why I own the car now. There are cosmic forces are in place that disallow certain people from owning Porsches.

Thanks very much for your above list of fixes. I sure would like to see some more posts here depicting what things we all have all had to do to our cars so we can help each other prepare for things to come. Boxster ownership can be costly, but with a little research and some work, the costs can and should be minimized.

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