2005 Porsche Boxster problems

UNKNOWN OR OTHER

Foam insulation blows out of windshield defroster vents. It is much worse when heat and fan are turned on. The windshield does not properly defrost and passengers are deluged with particulates and large chunks of black foam. This is a hazard to both breathing and visibility. Porsche is aware of the problem. Dealer says owners view as too expensive to fix. A recent Porsche Club of America newsletter article discusses the problem as a hazard and a paid advertisement pushes an alternative repair.

NHTSA complaint #11510582 — an unverified report by a vehicle owner.

VISIBILITY/WIPER

Foam insulation blows out of windshield defroster vents. It is much worse when heat and fan are turned on. The windshield does not properly defrost and passengers are deluged with particulates and large chunks of black foam. This is a hazard to both breathing and visibility. Porsche is aware of the problem. Dealer says owners view as too expensive to fix. A recent Porsche Club of America newsletter article discusses the problem as a hazard and a paid advertisement pushes an alternative repair.

NHTSA complaint #11510582 — an unverified report by a vehicle owner.

ENGINE

WHILE I WAS DRIVING ON A CITY STREET AT ABOUT 30 MPH, MY 2005 BOXSTER STARTED MAKING A RATTLING NOISE, THEN COMPLETELY DIED IN THE MIDDLE OF AN INTERSECTION ON A CITY STREET WITHOUT ANY PRIOR WARNING. AT THE SAME TIME, ALL OF THE WARNING LIGHTS CAME ON. I WAS ABLE TO PUT THE CAR IN NEUTRAL AND COAST TO THE SIDE OF THE ROAD. CAR WAS TOWED TO MY MECHANIC, WHO STATES IT IS AN INTERMEDIATE SHAFT BEARING ISSUE/FAILURE. HAD I BEEN DRIVING ON THE FREEWAY AT HIGH SPEED, I MOST LIKELY WOULD HAVE BEEN KILLED. I AM THE ORIGINAL OWNER OF THE CAR, IT HAS 128,000 MILES AND RECOMMENDED MAINTENANCE IS ALL UP TO DATE.

NHTSA complaint #11307839 — an unverified report by a vehicle owner.

POWER TRAIN

TL* THE CONTACT OWNS A 2005 PORSCHE BOXSTER. THE CONTACT WAS UNABLE TO DRIVE THE VEHICLE BECAUSE THE IGNITION KEY WAS LOCKED INSIDE THE IGNITION. THE CONTACT TOOK THE VEHICLE TO A CERTIFIED MECHANIC WHO DIAGNOSED THAT THE TRANSMISSION FAILED AND NEEDED A CABLE ADJUSTMENT WITH THE TRANSMISSION AND THE KEY. THE CONTACT STATED THAT THE FAILURE WAS DIRECTLY RELATED TO NHTSA CAMPAIGN NUMBER: 03V004000 (POWER TRAIN); HOWEVER, THE VEHICLE WAS NOT INCLUDED IN THE RECALL. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 47,000.

NHTSA complaint #10907121 — an unverified report by a vehicle owner.

EQUIPMENT ADAPTIVE/MOBILITY

TL* THE CONTACT OWNS A 2005 PORSCHE BOXSTER. THE CONTACT STATED WHILE TRAVELING APPROXIMATELY 55 MPH, THE ENGINE MADE A LOUD NOISE, VARIOUS WARNING LAMPS ILLUMINATED ON THE INSTRUMENT PANEL AND THE VEHICLE STALLED. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC. THE TECHNICIAN DIAGNOSED THAT THE MOTOR NEEDED TO BE REPLACED. THE INDEPENDENT MECHANIC SUGGESTED THAT THE VEHICLE BE TAKEN TO AN AUTHORIZED PORSCHE DEALER FOR REPAIRS. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER WHO VERIFIED THE FAILURE AND STATED THAT THE MOTOR HAD SELF DESTRUCTED AND NEEDED TO BE REPLACED. THE VEHICLE WAS TO BE INSPECTED AND REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 34,000. UPDATED 8/12/14*CN UPDATED 8/23/2017

NHTSA complaint #10598063 — an unverified report by a vehicle owner.

ENGINE

TL* THE CONTACT OWNS A 2005 PORSCHE BOXSTER. THE CONTACT STATED WHILE TRAVELING APPROXIMATELY 55 MPH, THE ENGINE MADE A LOUD NOISE, VARIOUS WARNING LAMPS ILLUMINATED ON THE INSTRUMENT PANEL AND THE VEHICLE STALLED. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC. THE TECHNICIAN DIAGNOSED THAT THE MOTOR NEEDED TO BE REPLACED. THE INDEPENDENT MECHANIC SUGGESTED THAT THE VEHICLE BE TAKEN TO AN AUTHORIZED PORSCHE DEALER FOR REPAIRS. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER WHO VERIFIED THE FAILURE AND STATED THAT THE MOTOR HAD SELF DESTRUCTED AND NEEDED TO BE REPLACED. THE VEHICLE WAS TO BE INSPECTED AND REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 34,000. UPDATED 8/12/14*CN UPDATED 8/23/2017

NHTSA complaint #10598063 — an unverified report by a vehicle owner.

SERVICE BRAKES

TL* THE CONTACT OWNS A 2005 PORSCHE BOXSTER. THE CONTACT STATED WHILE TRAVELING APPROXIMATELY 55 MPH, THE ENGINE MADE A LOUD NOISE, VARIOUS WARNING LAMPS ILLUMINATED ON THE INSTRUMENT PANEL AND THE VEHICLE STALLED. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC. THE TECHNICIAN DIAGNOSED THAT THE MOTOR NEEDED TO BE REPLACED. THE INDEPENDENT MECHANIC SUGGESTED THAT THE VEHICLE BE TAKEN TO AN AUTHORIZED PORSCHE DEALER FOR REPAIRS. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER WHO VERIFIED THE FAILURE AND STATED THAT THE MOTOR HAD SELF DESTRUCTED AND NEEDED TO BE REPLACED. THE VEHICLE WAS TO BE INSPECTED AND REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 34,000. UPDATED 8/12/14*CN UPDATED 8/23/2017

NHTSA complaint #10598063 — an unverified report by a vehicle owner.

POWER TRAIN

PULLING AWAY FROM A GREEN LIGHT IN TRAFFIC, THE ENGINE STARTED TO UPSHIFT INTO A HIGHER GEAR MUCH SOONER THAN NORMAL AND THE CAR FELT DOWN ON POWER. THE ENGINE SOUNDED AS THOUGH IT WAS RUNNING ON FEWER THAN NORMAL CYLINDERS. I STOPPED THE VEHICLE IMMEDIATELY & HAD IT TOWED TO A PORSCHE SPECIALIST. THEY TOLD ME IT WAS AN IMS (INTERMEDIATE SHAFT) BEARING FAILURE AND THAT IS WAS A KNOWN PROBLEM WITH M96 AND M97 PORSCHE ENGINES. MINE BEING AN M96 ENGINE.

NHTSA complaint #10525254 — an unverified report by a vehicle owner.

ENGINE

PULLING AWAY FROM A GREEN LIGHT IN TRAFFIC, THE ENGINE STARTED TO UPSHIFT INTO A HIGHER GEAR MUCH SOONER THAN NORMAL AND THE CAR FELT DOWN ON POWER. THE ENGINE SOUNDED AS THOUGH IT WAS RUNNING ON FEWER THAN NORMAL CYLINDERS. I STOPPED THE VEHICLE IMMEDIATELY & HAD IT TOWED TO A PORSCHE SPECIALIST. THEY TOLD ME IT WAS AN IMS (INTERMEDIATE SHAFT) BEARING FAILURE AND THAT IS WAS A KNOWN PROBLEM WITH M96 AND M97 PORSCHE ENGINES. MINE BEING AN M96 ENGINE.

NHTSA complaint #10525254 — an unverified report by a vehicle owner.

POWER TRAIN

THIS IS A VERY WELL KNOW IMS FAILURE ISSUE WITH PORSCHE BOXSTER WHICH CERTAINLY CALLS FOR A RECALL FROM PORSCHE. MY 2005 ENGINE WILL NEED TO BE REPLACED FOR 20K JUST BECAUSE OF THE VERY OBVIOUS DESIGN FLAW PORSCHE HAS IN ITS M96 ENGINES. I AM PRETTY SURE THERE HAVE BEEN NUMEROUS COMPLAINTS ABOUT THIS IN PAST BUT NOBODY HAS EVER HEEDED TO IT. I SINCERELY RECOMMEND SOME ONE TO PLEASE LOOK INTO AND ASK PORSCHE TO ACCEPT AND RECALL M96 ENGINES FAILING DUE TO IMS. ANY CAR EXPERT OR MECHANIC OR DEALERSHIP CAN VOUCH FOR THE DESIGN FLAW PORSCHE HAS. ITS POTENTIALLY FATAL TOO. I SINCERELY REQUEST SOMEONE TO LOOK INTO THIS COMPLAINT WITH UTTERMOST SINCERITY.

NHTSA complaint #10448412 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING

THIS IS A VERY WELL KNOW IMS FAILURE ISSUE WITH PORSCHE BOXSTER WHICH CERTAINLY CALLS FOR A RECALL FROM PORSCHE. MY 2005 ENGINE WILL NEED TO BE REPLACED FOR 20K JUST BECAUSE OF THE VERY OBVIOUS DESIGN FLAW PORSCHE HAS IN ITS M96 ENGINES. I AM PRETTY SURE THERE HAVE BEEN NUMEROUS COMPLAINTS ABOUT THIS IN PAST BUT NOBODY HAS EVER HEEDED TO IT. I SINCERELY RECOMMEND SOME ONE TO PLEASE LOOK INTO AND ASK PORSCHE TO ACCEPT AND RECALL M96 ENGINES FAILING DUE TO IMS. ANY CAR EXPERT OR MECHANIC OR DEALERSHIP CAN VOUCH FOR THE DESIGN FLAW PORSCHE HAS. ITS POTENTIALLY FATAL TOO. I SINCERELY REQUEST SOMEONE TO LOOK INTO THIS COMPLAINT WITH UTTERMOST SINCERITY.

NHTSA complaint #10448412 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING:ENGINE

CATASTROPHIC ENGINE DAMAGE DUE TO INTERMEDIATE SHAFT BEARING FAILURE. THERE ARE NO SIGNS THAT THE PART WILL FAIL. THERE IS A GRINDING NOISE IN THE ENGINE AND UPON STOPPING ALL THE OIL LEAKS OUT. AS SOON AS THE NOISE IS HEARD, THE ENGINE IS IRREPARABLE DAMAGED. INSTANT, CATASTROPHIC DAMAGE. ENGINE IS A TOTAL LOSS. BEARING IS A DEFECTIVE DESIGN AND HAS BEEN REDESIGNED IN NEWER MODELS.

NHTSA complaint #10419222 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING:ENGINE

TRAVELING 75MPH ON FREEWAY WHEN OIL & ENGINE LIGHTS CAME ON AND VEHICLE SIMULTANEOUSLY CAME TO DEAD STOP IN TRAFFIC; DIAGNOSED AS CATASTROPHIC ENGINE FAILURE BY DEALER SERVICE MGR., ENGINE REPLACED AT COST OF $17,000+. NO PRIOR WARNING. NO FAULT OF MY OWN PER SVC.MGR. 38K MILES ON 2005 VEHICLE, 3 MO OUT OF WARRANTY. MANY SIMILAR INCIDENTS REPORTED ON SEVERAL WEB SITES. SERVICE MGR REPORTED PORSCHE WELL AWARE OF THIS ISSUE BUT DOES NOTHING BECAUSE ITS TOO COSTLY TO REPAIR AND PREFERS TO HANDLE ON CASE BY CASE BASIS. SOMETIMES COVERS PART OF COST, SOMETIMES NOTHING. HAD I NOT BEEN ABLE TO BRAKE AND COAST TO STOP, I WOULD HAVE ROLLED OVER AND MOST LIKELY BEEN KILLED! DAMAGED ENGINE RETURNED TO PORSCHE IN GERMANY. I HAVE THE PART THAT BROKE FROM WHICH LITTLE BALLS SPEWED THROUGHOUT THE ENGINE. I AM INFORMED THIS OCCURS IN APPROX. 20% OF PORSCHE BOXSTERS AND OTHER PORSCHE VEHICLES FOR SEVERAL YEARS UNTIL THEY REDESIGNED THE BOLT IN 2010 MODELS. UNABLE TO DETERMINE HOW MANY INJURIES AND/OR DEATHS RESULTING FROM THESE CATASTROPHIC ENGINE FAILURES BECAUSE ACCIDENTS WOULD APPEAR TO BE FROM DRIVER ERROR AND NO ONE WOULD KNOW THE ENGINE FAILED UNDER THESE CIRCUMSTANCES! PORSCHE EMPLOYEES ARE INSTRUCTED NOT TO ACKNOWLEDGE KNOWING ANYTHING ABOUT THIS BEING AN ONGOING ISSUE AND NOT TO MAKE REPAIRS AT PORSCHE EXPENSE EXCEPT FOR THE CUSTOMERS WHO RAISE THE BIGGEST FUSS. ANOTHER BOXSTER WAS IN THE SHOP AT THE SAME TIME AS MINE FOR THE SAME PROBLEM. THE GOOGLE ADDRESS LINK BELOW SHOWS A PHOTO OF A BOXSTER CRANKSHAFT AND INTERMEDIATE SHAFT. ONE OF THE CONNECTING RODS BROKE NEAR THE PISTON WRIST PIN END AND THE INTERMEDIATE SHAFT IS DAMAGED. THIS CATASTROPHIC ENGINE FAILURE IS THE RESULT OF: 1) A SEIZED CONNECTING ROD BEARING, 2) A LOSS OF OIL PRESSURE, 3) BAD ORIGINAL COMPONENT DESIGN, 4) INTERMEDIATE SHAFT ASSEMBLY FAILURE (BOLTS OR MECHANICAL CONNECTION EG: WELD, CRIMP). THIS IS WHAT HAPPENED TO MY CAR. HTTP://WWW.RX8CLUB.COM/SHOWTHREAD.PHP?T=160705.

NHTSA complaint #10418537 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING:ENGINE

MY 2005 PORSCHE BOXSTER, 23K MI, HAD CATASTROPHIC ENGINE FAILURE AT IDLE. THE ENGINE STALLED;I WAS ABLE TO RESTART BUT A LOUD CLANGING NOISE CAME FROM ENGINE. THE CAR THEN DIED AGAIN. THE MECHANIC SAID IT WAS DUE TO AN INTERMEDIATE SHAFT (IMS) FAILURE; THE REQUIRED ENGINE REPLACEMENT IS $14K. THE MECHANIC SAID HE HAS HEARD OF SIGNIFICANT NUMBER OF IMS FAILURES (BUT PORSCHE HAS NOT NOTIFIED OWNERS). THERE WERE NO INJURIES, BUT CERTAINLY ENGINE FAILURE LIKE THIS COULD HAVE SERIOUS CONSEQUENCES AT FREEWAY SPEEDS. PORSCHE FORUMS ON INTERNET SHOW FREQUENCY OF FAILURES FROM THIS DEFECT (POORLY DESIGNED BEARING ASSEMBLY ON IMS) IS VERY HIGH, AS MUCH AS 8-11% IN ONE FORUM POLL.

NHTSA complaint #10405468 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING:ENGINE

2005 PORSCHE BOXSTER. CONSUMER STATES ENGINE MADE GRINDING A SOUND AND WOULD NOT START *TGW THE CONSUMER HAD THE VEHICLE TOWED TO THE DEALER, WHERE HE WAS INFORMED THE VEHICLE NEEDED A NEW ENGINE. THE CONSUMER STATED NO ONE COULD PROVIDE AN EXPLANATION AS TO WHY A VEHICLE WITH SUCH LOW MILES WOULD NEED A NEW ENGINE.

NHTSA complaint #10389269 — an unverified report by a vehicle owner.

FUEL SYSTEM, GASOLINE

TL*THE CONTACT 2005 PORSCHE BOXSTER. THE CONTACT STATED THAT WHILE THE VEHICLE WAS PARKED IN THE GARAGE HE SMELLED AN UNUSUAL ODOR. THE CONTACT DROVE THE VEHICLE OUT OF THE GARAGE AND NOTICED FUEL LEAKING. THE CONTACT CALLED THE MANUFACTURER WHO ADVISED HIM NOT TO DRIVE THE VEHICLE AND IT WAS TOWED TO A DEALER. THE DEALER REPLACED THE FUEL LINE. THE CONTACT STATED THE VEHICLE COULD HAVE CAUGHT ON FIRE WHILE DRIVING. THE FAILURE MILEAGE WAS 51,000. AFTER FURTHER INVESTIGATION THE PROBLEM WAS CAUSED BY SQUIRRELS EATING/ CLAWING THE FUEL LINE. IT WAS NOT A FAILURE OF THE PART. UPDATED 10/19/2011 *LN

NHTSA complaint #10375185 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

THIS IS THE SECOND TIME, AFTER A RAIN STORM, OUR 2005 PORSHE BOXSTER WOULD NOT START. DEALER SAYS IT IS WATER IN THE ELECTRICAL HARNESS. IS THIS A DESIGN FLAW?

NHTSA complaint #10230885 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING:ENGINE

I WAS DRIVING ON THE INNER LANE OF THE FREEWAY AT 65MPH. THE ENGINE SUDDENLY STALLED AND THE CHECK ENGINE LIGHT STARTED FLASHING. I MANAGED TO HAVE THE CAR SLIDING TOWARD THE SHOULDER AND GET OFF FREEWAY. THE CAR WASN'T ABLE TO RESTART AGAIN. A HIGHWAY PATROL CAME BY AND HELPED TO PUSH MY CAR TO WILDER SHOULDER FOR SAFETY. THE REAR BUMPER WAS DAMAGED IN THE PROCESS. THE CAR WAS TOWED TO THE DEALER FOR INSPECTION AND STILL IN THE SHOP NOW. THE MECHANIST SAID THE ENGINE NEED TO BE REPLACED.

NHTSA complaint #10228539 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING

DT*: THE CONTACT STATED WHILE DRIVING 35 MPH ON NORMAL ROAD CONDITIONS, AND WHEN STATIONARY, THERE WAS A VERY DISTINCT FUME SMELL COMING FROM THE ENGINE COMPARTMENT. THE SMELL WAS NOTICEABLE AND CAME IN THROUGH THE VENTS. THERE WERE NO WARNING SIGNALS PRIOR TO THE INCIDENT. THE VEHICLE WAS TAKEN TO A DEALER SEVERAL TIMES, WHERE THEY REPLACED THE LEFT AND RIGHT CYLINDER HEAD COVER; CYLINDER HEAD CUP SHIELD, MANIFOLD FUEL GASKET AND THE EXHAUST GASKET BUT THE SMELL PERSISTED.

NHTSA complaint #10174633 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING

DT*: THE CONTACT STATED WHILE DRIVING VARIOUS SPEEDS ON NORMAL ROAD CONDITIONS OR WHEN STATIONARY, THERE WAS A SMELL OF FUEL COMING FROM THE ENGINE COMPARTMENT. THE SMELL WAS NOTICEABLE AND CAME IN THROUGH THE VENTS. THERE WERE NO WARNING SIGNALS PRIOR TO THE INCIDENT. THE VEHICLE WAS TAKEN TO A DEALER SEVERAL TIMES, WHO REPLACED THE LEFT AND RIGHT CYLINDER HEAD COVER. ALSO, THE CYLINDER HEAD CUP SHIELD, MANIFOLD FUEL GASKET AND THE EXHAUST GASKET WERE REPLACED, BUT THE SMELL PERSISTED.

NHTSA complaint #10174112 — an unverified report by a vehicle owner.

AIR BAGS:ON-OFF SWITCH ASSEMBLY

2005 PORSCHE BOXSTER S, IS A 2 SEATER THAT LACKS ANY MEANS TO DISARM FRONT/SIDE PASSENGER AIRBAGS. DANGEROUS CONDITION FOR CHILD PASSENGER GIVEN THE LACK OF A BACK SEAT OR ALTERNATIVE SEATING. CERTAINTLY FORESEEABLE THAT CHILDREN WILL RIDE IN SUCH A VEHICLE.

NHTSA complaint #10158695 — an unverified report by a vehicle owner.