I wrote this article a few years ago and posted it over at the old Porsche Forums/German Auto Forums, and I still get a lot of emails every week about it.  Essentially, the same questions were popping up over and over, so I compiled some information related to my experiences working on 996’s. Pre Purchase Inspection: I can not recommend a PPI enough, unless you are a professional Porsche mechanic. Typically they run from $150-500, and is money well spent. …

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Every year auto dealers and manufacturers present their shiny new wares to the public at the Kansas City Auto Show. We headed down again this year to see what was new! I still cringe to think of the number of people, kids, etc that climb through these cars, many with no respect for the car, lol. Feel bad for the people buying these examples! Most of the cars there were…well….appliances IMHO. There are a lot of cool technology packages and …

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Took a couple of pictures of the camshafts this afternoon. This is the passenger intake camshaft. Notice the missing ring in the middle groove, there should be 3 on each cam. Again, this missing ring rides directly in path where this groove appeared in the front cam housing. And the driver side camshaft. All 3 rings present. And another close up of one of the cracked camshaft housing brackets.

996TT Top End

Tonight Stephen (PorschePhD) came by with the magical cam tools we needed to pull the motor down the rest of the way for inspection. This evening I pulled the driver’s side apart down to the cams and cleaned everything up so we could do both sides. Glad we did. As many 930 motors as I have pulled apart, I have never done anything internal to the 996TT motors as that was always Stephen’s department at the shop. It was a …

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Got the clutch installed this afternoon, and sent the car on it’s way. Since the disc was down to the metal, it did enough damage to the flywheel that I had to order a new flywheel. I think my machine shop could have probably turned the surface on the end mill and it would have been fine, but due to time constraints of the owners, we just went ahead with a new flywheel. New flywheel installed. What a new clutch …

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Drove down south of Louisburg today to diagnose a Boxster that was immobile. Figured out pretty fast that the clutch was completely shot. I assumed the disc hub had separated from the friction ring as there was zero movement from the car with the clutch disengaged. We had it towed up to the garage, and I started tearing it apart. Had the tow truck drop it straight onto the ramps for me. Lots of stuff to remove to get to …

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Started tearing down the passenger side camtower this afternoon. Found another metal shaving stuck to the cam sensor Cams exposed. Now I have to divert my attention to a 996 PPI. The good phd should be by this week with the cam tools we need so we can pull the cams and see what is going on.

Took some time this morning to pull the tranny, clutch, and get the motor up on the engine stand. Now to figure out what is going on in this motor. Again, what is involved in pulling the TT transaxles from the engine. Step 1, remove the plastic vent (3 bolts) Step two, remove the 10mm bolt and bracket. Step 3, pull the rubber plug that, along with the above bracket, hold the clutch shaft and bearings in place. This can …

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Been slow progress around here as Typhoid Mary brought something nasty home from work, so haven’t been feeling all that great, but I did finally get the motor dropped out of the car for engine work. Starting at the top and pulling lines, compressor, throttle body, cooling hoses, etc. At the bottom, subframe, axles, driveshaft, piping, etc And slowly starting to lower the engine. I had to modify the table to add a little width for stability, but after getting …

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Had a freind drop off his 996TT today for some long overdue engine work. Last year we started throwing cam actuator codes on the 2nd bank, and when replacing an actuator, I found a piece of metal shaving stuck to it. Not good. The light has persisted, so we are going to drop the motor and open it up and see what is going on with the variocam system. We also had some radiators to replace (passenger and center) as …

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