2004 C4S Cat failure

It just gets better - the C4S with the new engine now has a failing catalytic converter. Dealer is quoting $3,100.00 which I simply will not do. Car has 38K miles on the original cats and 500 miles on the engine. No codes, just noise, I actually thought the new engine had a problem so I dropped it at the dealer last night. Dealer is saying to just drive it and maybe whatever is loose will "blow out with use" or they can remove it and attempt "to shake the loose pieces out". Not sure about that advice at all. I called Pelican and they have an aftermarket for less than $600.00. I searched and saw many references to 200 cell cats so I am asking if anyone can help me understand my options, the car does have PSE. Money is somewhat of an object at this point, yet I prefer to do it right. Has anyone used an aftermarket converter on their 996? Any one think I would have an issue with the warranty on the new engine if I install an after market cat? Sort of stunned that my C2 touching 80K miles has not had nearly the costly issues that the low mileage C4S has had and continues to have. My mind is reeling with what is next and I let the dealer know again that I am less than happy that they blew it with my application for the 3rd party warranty in December. I purposely chose a top tier warranty that covered the entire emissions system, including the cats. Grrrrrr................. Thanks in advance for any advice/opinions.

Tough news to take for sure John! I'm going to keep my fingers crossed that our C2's are just charmed! That being said, if/when mine go (or before) I am going to go to FVD 200 cell cats. Expensive, but cheaper than OEM units and I have read more positive reviews on performance/sound appreciation than anything negative. Interested to see which way you will go. Pete

I went fabspeed 200 cel. No issues.

Yikes, John, what did I miss? What happened to the engine in your C4S and when? -Eric

John, what are your symptoms? Not to hijack the thread but every once in a while I get a very tinny rattle during normal driving like as if I ran over a piece of sheet metal or an aluminum can but when I check there is nothing on the road...It does NOT make noise over bumps, manhole covers etc. My perception is that is coming from the right rear.

Cats have an 8-year/80,000 mile warranty. It's a federal requirement for emission system components. It should be replaced at no charge, depending on when your car was put into service.

Quotes source posts: 10450473, 10450649, 10450466

It makes noise at idle and it is the right rear, I actually thought it was an internal engine noise, it is not a "tinny" sound, it is more like a clunking sound and it doesn't go away. Was just a fluke that I noticed it in that I was meeting my wife for dinner and left the house with out my cell phone, returned to the house to grab the phone and left the car running. When I came back out the noise was very obvious and I thought WTF, motor with just 500 miles and now what. It might make noise under throttle, not sure as I really wasn't listening for it and since we were real close to the dealer I just dropped it off last night. Thanks Dennis - car was put in service in August of 2004 so I am beyond the time limit. I asked the Service writer to call PCNA and see if they would do anything based on the mileage, he refused but he didn't even know that the emission system had a warranty beyond the basic so I asked him to ask the Service manager to make the call, hopefully they will give it a shot tomorrow. I did remind the Service writer that he also told me that they wouldn't do anything with the bad engine, but they did. Not sure what to think, they did provide the engine so maybe they will cover the cat or maybe they will think they already went above and beyond. If I wasn't out of work since January I would be a little less stressed and probably just take it in stride.

The engine should have been covered with out having to beg. https://rennlist.com/forums/996-foru...-mar-12-a.html

I would be in the 25% coverage class, I did research the class action proposal and mentioned it to the dealer thinking that 25% would be better than nothing.They said PCNA never referenced the class action settlement at all. They were more concerned about my ownership history and history of dealer service on both of my cars. I do agree with you, begging should not be required.

You should make sure that any aftermarket cats will not affect your warranty on your new motor. I mean it technically shouldn't but you know how dealers can get. Another alternative is to get a set of low mileage used ones. I've seen these pop up from time to time around $300 range on evil bay.

http://www.ebay.com/itm/02-PORSCHE-9...eb2795&vxp=mtr http://www.ebay.com/itm/Catalytic-Co...a1309e&vxp=mtr

John, you came out so good on your new engine, I wouldnt stress too much about buying cat(s). May not be a coincidence that the catalyst broke up after the install. One of the boneheads in the shop may have dropped the exhaust on the shop floor while removing, moving, installing, whatever, who knows what, causing the piece to come loose. You can try removing the suspect cat and if the broken piece is at either end of the catalyst, you may be able to dump it out. Its the typical "honeycomb" type catalyst.

Buy 200 cell cats. Cargraphic, FVD or fabspeed all offer them. The sound coupled with PSE is incredible.

Both of my cats were replaced under warranty before I hit 80K miles. If they fail again, I'm going with aftermarket 200 cell cats.

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This is what I did! I went with Cargraphic due to availability and price. I couldn't be happier. It sounds sublime.

Dealer is not willing to attempt assitance from PCNA because I am beyond the eight years (and they even stated that Porsche provided enough assistance with the engine). I asked them if by chance the cat was dropped during the engine swap and of course they said no because they inspected it for dents. Question on the 200 cell cats - I read while searching that some folks have complained about low end lag, and noticeable reduction in low end torque. Any real issues there?

Update - picked up the car tonight and have decided to simply live with it for the time being, sounds as if the noise is not a critical issue, just an annoyance at this point, and I only hear it at idle, even with the windows and roof open. Still interested in learning more about the 200 cell cats as I am considering that option.

Try a different dealer. Go in and honestly explain the situation and that all you want is someone to ask PCNA. The dealers are not owned by PCNA and cannot make decisions for PCNA, they work for your money. You are their customer, for them to tell you that Porsche has done enough for you is not really a good answer. The mothership should have an opportunity to respond themselves. Or just write a letter to PCNA, it'll cost you 46 cents...