Pre-Purchase Inspection
I see a lot of people who go online and ask if they need a to do a PPI. The answer is unequivocally yes. You should always get a proper PPI, and I highly recommend having it done by someone familar with the Boxster, and the M96 engine. Repairs in these cars are not cheap. If you find a Boxster for under $10k, you will probably have spent $10k by the time you get it running.
Always ask for documents that can verify a cars service history, especially if they claim the IMS was upgraded.
Here is a great Porsche Club of America video on 986/996 pre-purchase inspections.
Always ask for documents that can verify a cars service history, especially if they claim the IMS was upgraded.
Here is a great Porsche Club of America video on 986/996 pre-purchase inspections.
Part Numbers
I am a huge promponent of using part numbers for several reasons. The main ones are that they allow you to know exactly what you are getting (color, year, fitment, etc), and can help save a lot of money. By searching the Porsche 986 Parts Catalogue (or online) and identifying a part number, you can then search for the best price online, and know exactly what you are getting. I have found that most of the time, websites that use part numbers are significantly less expensive that those that do not.
You can find the Porsche 986 Part Manual here.
The last two digits in the part number are the version number. When searching for a part number it may show up as being superseded by a part with a newer version number (last two digits). Occasionally, a part number will be superseded by a new part number, for the 986 this is often a number that starts with 996, and rarely 997.
You can find the Porsche 986 Part Manual here.
The last two digits in the part number are the version number. When searching for a part number it may show up as being superseded by a part with a newer version number (last two digits). Occasionally, a part number will be superseded by a new part number, for the 986 this is often a number that starts with 996, and rarely 997.
Phone Connector
Under the center console is an unused plug, known as the phone connector. This is because it provides the wiring for the extremely rare optional telephone. The wiring includes 12V Constant Power, 12V Switched Power, Ground, and Telephone Mute. The 12V power and ground are very useful for DIY projects.
If you find a stray plug under you center console (normally behind the batwing trim), don't panic, it is just the phone connector.
The wire colors are: (verify colors for your year)
Red/Green - 12V Constant
Green/Black - 12V Switched
Brown - Ground
Yellow/Black - Phone Mute
If you find a stray plug under you center console (normally behind the batwing trim), don't panic, it is just the phone connector.
The wire colors are: (verify colors for your year)
Red/Green - 12V Constant
Green/Black - 12V Switched
Brown - Ground
Yellow/Black - Phone Mute
Soft Top
The 986 soft top is made from german canvas. It is important to keep the top clean and waterproof to ensure it stays in good condition. While most people use RaggTop Cleaner and Waterproofer, I prefer 303 Fabric Cleaner and Renovo UltraProofer. The Renovo brushes on, which I feel provides a better coating, and it also eliminates the possibility of overspray on the paint. I also use Plexus to clean and maintain the plastic rear window, many people also like to use Novus.
If/when the plastic window cracks, there are several aftermarket solutions that offer glass windows. The only drawback is that due to the design of the supporting top bows (horizontal supports), aftermarket tops have narrow glass windows (about 11-12" high), compared to the redesigned '03-'04 top frame with a larger glass window. The '03-'04 top and frame can be retrofitted on '00-'02 Boxsters as a direct bolt on replacement. The '03-'04 top can also be retrofitted to '97-'99 Boxsters but the top transmission and cables must also be replaced.
If/when the plastic window cracks, there are several aftermarket solutions that offer glass windows. The only drawback is that due to the design of the supporting top bows (horizontal supports), aftermarket tops have narrow glass windows (about 11-12" high), compared to the redesigned '03-'04 top frame with a larger glass window. The '03-'04 top and frame can be retrofitted on '00-'02 Boxsters as a direct bolt on replacement. The '03-'04 top can also be retrofitted to '97-'99 Boxsters but the top transmission and cables must also be replaced.
Engine Failure
The 986 engine is prone to some spectatular modes of engine failure. If you have been on any Porsche forums you have probably heard about IMS failure. However, I would encourage everyone to learn the facts before they blindly spend money on a solution they may not need.
RMS
The Rear Main Seal failure causes all of the oil to drain from the engine, resulting in catostrophic engine failure. RMS failure can often be caught ahead of time, signaled by an oil leak coming from the engine area. The solution is to replace the Rear Main seal before it fails. Correctly replacing the seal requires meticulous attention to detail, so make sure you use a reputable shop/dealer.
IMS
While Intermediate Shaft failures can affect any model year 986, it is extremely uncommon for the dual row IMS found in the '97-'99 Boxster to experience a failure. In 2000, Porsche redesigned the IMS, from double row to single row to reduce vibrations and noise, but inadvertently creating the infamous IMS issue. Boxster's from 2000 may have a single or dual row IMS, which can only be determined by removing the bearing itself. Any 986 made from 2001+ has the single row IMS, which is prone to failure.
The IMS often fails with no warning except for a sound similar to a coin bouncing around in the engine compartment, which sometimes precedes the failure by a few seconds. A contributing factor to IMS failure is a lack of oil lubrication. It may also be possible to catch IMS failure by monitoring cam deviations.
Do to the attention this issue has received there are now multiple 'fixes' and warning systems available, and there is a plethora of information available online regarding this issue. If you have a '00+ Boxster installing an upgraded IMS makes a lot of sense, especially if you will already have the car apart for a new clutch. However, pre-'99 the failure rate for the IMS is sub-1%, per the IMS class action lawsuit.
If you are purchasing a used Boxster that claims to have an upgraded IMS, make sure you can verify it actually has one. Ask to see a receipt, sometimes their will be a sticker on the door.
Slipped Sleeve
This issue affected a limited number of 1999 Boxsters, made between 10/1/98 - 3/31/99. Unable to keep up with manufacturing demand for the popular Boxster, Porsche manufactured a limited number of Boxster's with faulty cylinder sleeves.
You can check the date of manufacture on the driver's door sticker to see if you manufacture date was affected. The vast majority of these Boxsters have had their engine's replaced under warranty as the failure often occured within the first 30,000 miles. You can also compare the engine serial number to your car's serial number to determine if the engine has been replaced.
D-Chunk
Similar to slipped sleave failure, this one has become increasingly rare as it mostly affected Boxsters within the first 30,000 miles. It primilary affected earlier model years, when part of the cylinder would break off in a D-shaped chunk.
RMS
The Rear Main Seal failure causes all of the oil to drain from the engine, resulting in catostrophic engine failure. RMS failure can often be caught ahead of time, signaled by an oil leak coming from the engine area. The solution is to replace the Rear Main seal before it fails. Correctly replacing the seal requires meticulous attention to detail, so make sure you use a reputable shop/dealer.
IMS
While Intermediate Shaft failures can affect any model year 986, it is extremely uncommon for the dual row IMS found in the '97-'99 Boxster to experience a failure. In 2000, Porsche redesigned the IMS, from double row to single row to reduce vibrations and noise, but inadvertently creating the infamous IMS issue. Boxster's from 2000 may have a single or dual row IMS, which can only be determined by removing the bearing itself. Any 986 made from 2001+ has the single row IMS, which is prone to failure.
The IMS often fails with no warning except for a sound similar to a coin bouncing around in the engine compartment, which sometimes precedes the failure by a few seconds. A contributing factor to IMS failure is a lack of oil lubrication. It may also be possible to catch IMS failure by monitoring cam deviations.
Do to the attention this issue has received there are now multiple 'fixes' and warning systems available, and there is a plethora of information available online regarding this issue. If you have a '00+ Boxster installing an upgraded IMS makes a lot of sense, especially if you will already have the car apart for a new clutch. However, pre-'99 the failure rate for the IMS is sub-1%, per the IMS class action lawsuit.
If you are purchasing a used Boxster that claims to have an upgraded IMS, make sure you can verify it actually has one. Ask to see a receipt, sometimes their will be a sticker on the door.
Slipped Sleeve
This issue affected a limited number of 1999 Boxsters, made between 10/1/98 - 3/31/99. Unable to keep up with manufacturing demand for the popular Boxster, Porsche manufactured a limited number of Boxster's with faulty cylinder sleeves.
You can check the date of manufacture on the driver's door sticker to see if you manufacture date was affected. The vast majority of these Boxsters have had their engine's replaced under warranty as the failure often occured within the first 30,000 miles. You can also compare the engine serial number to your car's serial number to determine if the engine has been replaced.
D-Chunk
Similar to slipped sleave failure, this one has become increasingly rare as it mostly affected Boxsters within the first 30,000 miles. It primilary affected earlier model years, when part of the cylinder would break off in a D-shaped chunk.
Save the Flash
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The Save the Flash icon used to link a website with the following explaination:
"Not so many years ago, spotting another Porsche on the road was a welcome event. Without ever meeting the driver, you could rest assured that you had encountered a kindred spirit; someone who shared your appreciation of one of the best engineered performance cars in the world. As a sign of acknowledgment, the drivers would flash their headlights. Though some still practice the tradition, many old owners have gotten lazy and many new owners have never learned this important tradition. Owning a Porsche is a unique experience. Do your part to preserve the experience... keep the flash alive!" Link to website archive |
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Interesting Tidbits
- Cosmetically, the Boxster (986) and early Carrera (996) are nearly identical from the doors forward.
- The 986 was inspired by the Porsche 550 Spyder, most widely know as the car James Dean was driving when he was killed.
- The 986 is widely considered to be one of the best handling cars ever made, with near perfect 50/50 weight distribution due to its mid-engine design. This has led to early 2.5L Boxster gaining their own Spec Racing class.
- The front trunk (frunk) on the 986 can fit a full sized keg.
- The rear trunk can fit a full set of golf clubs, however you may have to take them out of the bag.
- The driver's door lock can be held down in either direction with the key to open or close the windows while outside the car.
Disclaimer
This website is a personal project, and any information contained on this website should be independently verified. I accept no liability and/or responsibility for the accuracy of any information on this website, and/or any damage you incur from reading or following any of the information on this website. This website contains documentation of my own modifications, upgrades, and other work, however your results may differ. I encourage everyone to do their own research and verify any information themselves. This website may be directly linked to without specific permission, but the contents may not be copied, hosted, transmitted, etc in any medium without express permission. Thank you!
This website is a personal project, and any information contained on this website should be independently verified. I accept no liability and/or responsibility for the accuracy of any information on this website, and/or any damage you incur from reading or following any of the information on this website. This website contains documentation of my own modifications, upgrades, and other work, however your results may differ. I encourage everyone to do their own research and verify any information themselves. This website may be directly linked to without specific permission, but the contents may not be copied, hosted, transmitted, etc in any medium without express permission. Thank you!
