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    2005 997 Intermediate Shaft Failure - Aaargh

    Bad news! 24K on the car and the intermediate shaft has blown. Car is now in the shop with the engine and transmission out, pending further discussions between the OPC and Porsche of NA on the next steps. I ran a search on this forum for intermediate shaft, and didn't find anything...on other forums, this appears to be a known issue for 996 engines and MY05 997's, while MY06 997's and newer apparently have a newer (or none?) intermediate shaft.

    Hoping some of you can share any information or sources of information on this unfortunate issue. Luckily what I have seen on other forums suggests that Porsche has been for the most part willing to replace the entire engine in this situation since it's a known defect, but I'd like to arm myself with as much information as possible for what will likely be a protracted event in getting this fixed.

    Thanks to all for any valuable information you can share...

    Paul

    Re: 2005 997 Intermediate Shaft Failure - Aaargh

    Warranty will cover it. Buddy of mine had a 986 (2003?) with IS failure. He got a new engine block.

    AFAIK, When you get new engine they change all the numbers so everything matches. IOW, years from now the new engine will appear to have been original to the car.

    Soooo, this is _good_ news: your first 24k miles were "free."

    Bad news: break in time again!


    _OR_ (either way you're covered )

    Re: 2005 997 Intermediate Shaft Failure - Aaargh

    Thanks MMD...true enough, warranty is good until Feb 2009 luckily, so I am covered on that aspect. Would it be fair to say that the new engine, if they install a complete new one, would also have an additional 4/50 warranty, while the rest of the vehicle would not, unless I purchase an extended warranty.

    On that subject, is it the general consensus of most P-car owners to get an extended warranty? I've yet to price it with the OPC but might as well at this point to see if it makes sense. What I am a little bit concerned with is "diminished value", as perhaps any future buyer will see that the car had a new engine unless they do as you say, i.e. align all the numbers etc.

    All in all...break in again would be fun!

    Re: 2005 997 Intermediate Shaft Failure - Aaargh

    Not sure about specifics except "diminished value" is not a problem. Lots of new Porsches have engine replacements and since they are done by Porsche and under warranty nobody cares. It just means the car is in better shape since the engine is newer than the car, right? It was a while ago when my friend got his done. I think there's a bit of extra warranty coverage involved but I forgot details.

    Ahhhhh..., Break in..., Those were the good old days!

    Re: 2005 997 Intermediate Shaft Failure - Aaargh

    Encouraging news then all in all...thanks again MMD...appreciate the information.

    Cheers.

    Re: 2005 997 Intermediate Shaft Failure - Aaargh

    Mine was covered by warranty and the entire engine was replaced

    Re: 2005 997 Intermediate Shaft Failure - Aaargh

    What's the failure mode of the intermediate shaft? Does it physically break?

    Re: 2005 997 Intermediate Shaft Failure - Aaargh

    you are incredibly lucky to get warranty coverage.

    someone i know just had his intermediate shaft break on his 2005 C2S tip, and he was denied warranty coverage because of an aftermarket intake and exhaust.

    it cost him $US 19k to get a new engine with core exchange from Porsche.

    Re: 2005 997 Intermediate Shaft Failure - Aaargh

    Quote:
    Greentree said:
    What's the failure mode of the intermediate shaft? Does it physically break?



    AFAIK, a bolt breaks and the shaft goes flying into history. NOT an uncommon problem; Porsche knows it well.

    Here's a pic (I-shaft has red line). IS transfers power from crank to camshafts via chains. Hence it's called _intermediate_.

    Re: 2005 997 Intermediate Shaft Failure - Aaargh

    Quote:
    MMD said:
    Quote:
    Greentree said:
    What's the failure mode of the intermediate shaft? Does it physically break?



    AFAIK, a bolt breaks and the shaft goes flying into history. NOT an uncommon problem; Porsche knows it well.

    Here's a pic (I-shaft has red line). IS transfers power from crank to camshafts via chains. Hence it's called _intermediate_.



    No IS on the new 997.2 engines. One thing less to break!

    Re: 2005 997 Intermediate Shaft Failure - Aaargh

    I have heard of two cases in SPain of MY05 997s with this intermediated shaft failure, engines were replaced under warranty.

    Re: 2005 997 Intermediate Shaft Failure - Aaargh

    Thanks again everyone...no definitive news yet from the OPC, I imagine they are still in discussions with Porsche N.A. $19K for a new engine...that would be brutal if it were not covered under warranty...

    Re: 2005 997 Intermediate Shaft Failure - Aaargh

    Quote:
    PJPR said:
    Thanks again everyone...no definitive news yet from the OPC, I imagine they are still in discussions with Porsche N.A. $19K for a new engine...that would be brutal if it were not covered under warranty...



    A friend's 996C4S was covered fully with new engine more than a year after warranty expired.
    As it is a well known problem, Porsche have been flexible. I hope you get the same treatment.

    Re: 2005 997 Intermediate Shaft Failure - Aaargh

    Thanks reginos.

    Good news indeed tonight from the OPC! A new engine covered under warranty has been ordered and should arrive by the end of the week. It also carries with it another 2 years and unlimited miles warranty on the new engine which is fantastic since the my original warranty was expiring in Feb 09.

    This is the kind of customer service that will make me a repeat Porsche customer!

    Thanks again everyone for your insights.

     
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