Intermediate Shaft Failure

[CGB]

Folks,

Last night I was about to start my '02 996 cab with 20,000 miles and the electronic oil gauge said I was below minimum. When I went around to the back of the car to check the oil with the dipstick, I saw that all (or what seemed like all) of the oil was on the ground.

I had the car towed to the dealer and today they told me that it appeared that a bolt on the intermediate shaft had sheared off. Presumably this took out the seal causing the oil leak. They were waiting for Porsche to advise them whether they should disassemble the engine - I suppose to inspect for damage and potentially repair it or to just replace the engine.

I'm not sure how much difference either option makes or whether I will even have a choice in the matter.

I don't post often, but I have been reading this board and others on and off for a few years now and I don't recall hearing about this problem. Has anyone else had an experience like this and does anyone have any recommendations?

[Loren]

Sorry, to hear about your trouble. I've heard of a couple of these.

Here is a link to one of them:

http://www.renntech.org/forums/index.php?s...indpost&p=35370

[macsak]

it happened to me twice

2002 Boxster S and 2004 Boxster 550 SE

bad luck/karma on my part, i guess

you will get a replacement engine that is exactly the same as the one you had before

there is no repair option

sorry you had this problem

aloha

steve

Folks,

Last night I was about to start my '02 996 cab with 20,000 miles and the electronic oil gauge said I was below minimum. When I went around to the back of the car to check the oil with the dipstick, I saw that all (or what seemed like all) of the oil was on the ground.

I had the car towed to the dealer and today they told me that it appeared that a bolt on the intermediate shaft had sheared off. Presumably this took out the seal causing the oil leak. They were waiting for Porsche to advise them whether they should disassemble the engine - I suppose to inspect for damage and potentially repair it or to just replace the engine.

I'm not sure how much difference either option makes or whether I will even have a choice in the matter.

I don't post often, but I have been reading this board and others on and off for a few years now and I don't recall hearing about this problem. Has anyone else had an experience like this and does anyone have any recommendations?

[Tool Pants]

This is a 2003 2.7 Boxster where this happened. The threaded end of the shaft sheared off with the nut still attached. I was told this happens because Porsche switched from a double roller bearing to a single at the end of the shaft. The top green line is the shaft. The bottom is the broken end with the nut.

[CGB]

Thanks for the responses. The service manager called today to say that they found metal parts in the oil filter and therefore will be replacing the engine. Is there anything I should be aware of with a swap? Or is this pretty routine by now?

They are loaning me a Cayenne until the job is done - which they expect will be Monday.

[Loren]

Just remember new engine = new breakin period.

Good Luck!

[Danyol]

I had this happen to mine at 18k before I bought it (at 19k). Touch wood, I have 30k on the new engine with no further issues.

If oil ends up throughout the bellhousing does that mean the clutch should have been replaced (not sure if this was done on mine)? No apparent clutch issues, just curious.

[CGB]

Good point about the clutch - I was wondering that myself.

Does anyone have any thoughts on whether anything other than the engine itself might have been damaged?