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Leading reported evidence
Install metal sleeve
Performed · outcome unconfirmed
No successful repair reported for this finding.
0
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0
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1
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Read evidence and context
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1
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Performed · outcome unconfirmed · Original poster
Because this fatal flaw put them behind production goals they installed a metal sleeve that also had a fatal flaw!
Leading evidence: 'Install metal sleeve' (no explicit attributable resolution; this is a reported action or suggestion). Across 1 matching discussions, The most frequently discussed action is 'Install metal sleeve' (1 discussions). For that action, 0 discussions report a resolution and 0 report an unsuccessful attempt. No action has an explicit, attributable resolution report under the current rules. These are forum reports and suggestions, not a confirmed diagnosis.
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1
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Performed · outcome unconfirmed
Basically, new cars were sold with �repaired engines�
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Discussions that performed work without a confirmed outcome
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Performed · outcome unconfirmed
Since "steel" IS a metal composite, I think the Porsche engineer/instructor, who advised us on this, used the term steel due to the metal matrix composite base metal is iron, same as it is in steel.
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Discussions that contain suggestions
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Suggestion
Raby, I had forgotten about the Porsche factory repair of the M96/20 engines back in 99.
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Suggestion
As far as I know this is only an issue with M96/20 2.5 Boxster engines, and was not an issue with the M96/01 or any other 3.4 engines of 1999..Most of these engine have been replaced by Porsche under warranty, but if you find a 99 986 "cream puff" with low miles, mite want to be aware of this..
Discussions that performed work without a confirmed outcome
1
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0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Performed · outcome unconfirmed
Since "steel" IS a metal composite, I think the Porsche engineer/instructor, who advised us on this, used the term steel due to the metal matrix composite base metal is iron, same as it is in steel.
Counts describe captured discussions, not unique people or a diagnosis. Author identities are not reliably stored. Exact duplicate evidence is counted once across matching discussions; one discussion counts at most once per action/state. Multiple repairs reported together remain a combination. Suggestions and failed attempts do not establish a fix. Matches cover whole discussions and can include related faults, model variants and incomplete threads.
8 eligible posts · 0 unverified posts · 1 discussions match the subject in their title or opening post.
Rennlist: 1 discussions
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Generation: 20261026T212127Z · outcome-qualification-6. Deterministic extraction; no AI model inference. How we use sources
Great! Thanks for taking the time to do these Jake. There will always be naysayers, and critics, but the silent majority greatly appreciate your efforts and willingness to share knowledge.
Thanks for the video Rev. Raby, I had forgotten about the Porsche factory repair of the M96/20 engines back in 99. I was recently asked if Porsche ever put any steel sleeves in m96 engines and I replied no, but I had forgotten about when there was a fire at the engine plant in 99, the engine case casting machines were moved to another site and reset-up. There was a problem with core shift on the newly set-up machines that put production behind, and Porsche repaired the blocks by installing steel sleeves in some cylinders and sometimes all 6 cylinders.But there was a mistake in the machining of the radius at the "top hat" of the interface between the sleeve and the case that resulted in a crack of the sleeve "top hat" when pressed into place. After a few thousand miles (less than 30k) the "top hat" would beak off or the sleeve slip down and hit the crank, locking the engine. As far as I know this is only an issue with M96/20 2.5 Boxster engines, and was not an issue with the M96/01 or any other 3.4 engines of 1999..Most of these engine have been replaced by Porsche under warranty, but if you find a 99 986 "cream puff" with low miles, mite want to be aware of this..
Since "steel" IS a metal composite, I think the Porsche engineer/instructor, who advised us on this, used the term steel due to the metal matrix composite base metal is iron, same as it is in steel. Without having a name for the specific metal matrix composite , he used the well understood term steel.
So let me get this straight. Porsche moved their casting machinery and in the new location the machines produced blocks with a fatal flaw. Because this fatal flaw put them behind production goals they installed a metal sleeve that also had a fatal flaw! Right? That is the true definition of not following established quality manufacturing processes and being driven solely by production requirements. Unfortunately, I saw examples of this from manufacturers my entire career. Glad I didn't have one of those cars. One question: did Porsche fix the defective/soon to fail cars they produced? If they did my guess is it was much more expensive in so many ways than not meeting the original production goals would have been in the first place.
Jim Pasha (RIP) wrote the full story on this occurrence in the December 2008 issue of Excellence Magazine. Ironically that�s when my engine program was first featured for these engines.
Basically, new cars were sold with �repaired engines�
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