Coolant Line Failures- NHTSA
05-11-2013 | 11:23 PM
#106
Racer
Joined: Oct 2011
Posts: 477
Likes: 0
From: SF Bay Area
today at the track an 04' gt3 dumped coolant on the track in front of me. It started a little after a braking zone. I was a few car lengths behind when it happened, and ended up going straight off the track because I couldn't fully stop or turn. Luckily there was no damage to either cars.
05-13-2013 | 01:50 PM
#108
7th Gear
Joined: Jul 2008
Posts: 7
Likes: 0
From: Clarksburg,Ontario Canada
2004 GT3 Cooling System Failures
Yesterday marked the fourth or fifth time I've experienced a massive cooling system failure on my 2004 GT3. The first failure was in 2006 at Summit Point, W VA when the car had about 60,000km on the clock. A bonded-in aluminum tube (spigot) on the coolant distribution manifold popped off, resulting in a massive, instant coolant loss at the turn-in to corner 1. I made it through but several cars following went off due to the slippery pavement.
My worst personal incident was at Watkins Glen in 2008 when another spigot popped going into the climbing esses (corner 2). My loaded left rear tire was suddenly lubricated with hot antifreeze and the resulting spin caused me to crash into the outside Armco.
Yesterday another spigot popped out of its housing just under the alternator. Fortunately, the Upper Canada Region of the PCA has required that any Metzger-engine must run water or have all coolant fittings pinned or welded and the water I spilled onto the track surface quickly evaporated without causing much of a delay.
My engine has now driven 135,000 km and, except for these cooling issues, has been relatively problem-free. I tried to register on the NHTSA complaint website but cannot do so with a Canadian car.
What can I do to help us get Porsche to acknowledge that there is a serious problem with these cooling systems?
My worst personal incident was at Watkins Glen in 2008 when another spigot popped going into the climbing esses (corner 2). My loaded left rear tire was suddenly lubricated with hot antifreeze and the resulting spin caused me to crash into the outside Armco.
Yesterday another spigot popped out of its housing just under the alternator. Fortunately, the Upper Canada Region of the PCA has required that any Metzger-engine must run water or have all coolant fittings pinned or welded and the water I spilled onto the track surface quickly evaporated without causing much of a delay.
My engine has now driven 135,000 km and, except for these cooling issues, has been relatively problem-free. I tried to register on the NHTSA complaint website but cannot do so with a Canadian car.
What can I do to help us get Porsche to acknowledge that there is a serious problem with these cooling systems?
05-13-2013 | 02:34 PM
#109
Rennlist Member
Joined: Dec 2005
Posts: 346
Likes: 0
From: Colorado
Martin,
PM me your contact info and I will forward you the Investigators contact info. maybe he'll be able to use the info as supporting evidence.
PM me your contact info and I will forward you the Investigators contact info. maybe he'll be able to use the info as supporting evidence.
Yesterday marked the fourth or fifth time I've experienced a massive cooling system failure on my 2004 GT3. The first failure was in 2006 at Summit Point, W VA when the car had about 60,000km on the clock. A bonded-in aluminum tube (spigot) on the coolant distribution manifold popped off, resulting in a massive, instant coolant loss at the turn-in to corner 1. I made it through but several cars following went off due to the slippery pavement.
My worst personal incident was at Watkins Glen in 2008 when another spigot popped going into the climbing esses (corner 2). My loaded left rear tire was suddenly lubricated with hot antifreeze and the resulting spin caused me to crash into the outside Armco.
Yesterday another spigot popped out of its housing just under the alternator. Fortunately, the Upper Canada Region of the PCA has required that any Metzger-engine must run water or have all coolant fittings pinned or welded and the water I spilled onto the track surface quickly evaporated without causing much of a delay.
My engine has now driven 135,000 km and, except for these cooling issues, has been relatively problem-free. I tried to register on the NHTSA complaint website but cannot do so with a Canadian car.
What can I do to help us get Porsche to acknowledge that there is a serious problem with these cooling systems?
My worst personal incident was at Watkins Glen in 2008 when another spigot popped going into the climbing esses (corner 2). My loaded left rear tire was suddenly lubricated with hot antifreeze and the resulting spin caused me to crash into the outside Armco.
Yesterday another spigot popped out of its housing just under the alternator. Fortunately, the Upper Canada Region of the PCA has required that any Metzger-engine must run water or have all coolant fittings pinned or welded and the water I spilled onto the track surface quickly evaporated without causing much of a delay.
My engine has now driven 135,000 km and, except for these cooling issues, has been relatively problem-free. I tried to register on the NHTSA complaint website but cannot do so with a Canadian car.
What can I do to help us get Porsche to acknowledge that there is a serious problem with these cooling systems?
05-13-2013 | 02:55 PM
#110
Addict
Lifetime Rennlist
Member
Lifetime Rennlist
Member
Joined: Sep 2002
Posts: 4,608
Likes: 13
From: Montreal, QC
Yesterday marked the fourth or fifth time I've experienced a massive cooling system failure on my 2004 GT3. The first failure was in 2006 at Summit Point, W VA when the car had about 60,000km on the clock. A bonded-in aluminum tube (spigot) on the coolant distribution manifold popped off, resulting in a massive, instant coolant loss at the turn-in to corner 1. I made it through but several cars following went off due to the slippery pavement.
My worst personal incident was at Watkins Glen in 2008 when another spigot popped going into the climbing esses (corner 2). My loaded left rear tire was suddenly lubricated with hot antifreeze and the resulting spin caused me to crash into the outside Armco.
Yesterday another spigot popped out of its housing just under the alternator. Fortunately, the Upper Canada Region of the PCA has required that any Metzger-engine must run water or have all coolant fittings pinned or welded and the water I spilled onto the track surface quickly evaporated without causing much of a delay.
My engine has now driven 135,000 km and, except for these cooling issues, has been relatively problem-free. I tried to register on the NHTSA complaint website but cannot do so with a Canadian car.
What can I do to help us get Porsche to acknowledge that there is a serious problem with these cooling systems?
My worst personal incident was at Watkins Glen in 2008 when another spigot popped going into the climbing esses (corner 2). My loaded left rear tire was suddenly lubricated with hot antifreeze and the resulting spin caused me to crash into the outside Armco.
Yesterday another spigot popped out of its housing just under the alternator. Fortunately, the Upper Canada Region of the PCA has required that any Metzger-engine must run water or have all coolant fittings pinned or welded and the water I spilled onto the track surface quickly evaporated without causing much of a delay.
My engine has now driven 135,000 km and, except for these cooling issues, has been relatively problem-free. I tried to register on the NHTSA complaint website but cannot do so with a Canadian car.
What can I do to help us get Porsche to acknowledge that there is a serious problem with these cooling systems?
05-13-2013 | 02:59 PM
#111
Thread Starter
Race Car
Joined: Feb 2003
Posts: 3,935
Likes: 9
From: New Jersey
Let him know it's happening on Canadian cars as well. (investigator's email address removed)- pm if needed. Oh- by the way Martin- time to get them fixed correctly.
Last edited by Gofishracing; 05-14-2013 at 03:32 PM.
05-13-2013 | 03:26 PM
#113
7th Gear
Joined: Jul 2008
Posts: 7
Likes: 0
From: Clarksburg,Ontario Canada
GT3 Coolant System Problems
I've always had the GT3 repaired at a Porsche Dealer and the factory claims there is no problem. They just replaced the "malfunctioning" component!
I've owned this car from new since November 1, 2003. It has 135,000 km on the odometer and the car is now getting every spigot tube fixed properly.
My GT3 has done over 250 track days without any serious problems except the cooling system failures. No oil leaks and the original clutch as well. I did have the rear shocks re-built two years ago. The shift linkage can break at the base of the shifter, but the fix isn't too difficult if you bring a spare part with you.
Hopefully the GT3 will accompany me to a DE event at Mid-Ohio this coming weekend.
I've owned this car from new since November 1, 2003. It has 135,000 km on the odometer and the car is now getting every spigot tube fixed properly.
My GT3 has done over 250 track days without any serious problems except the cooling system failures. No oil leaks and the original clutch as well. I did have the rear shocks re-built two years ago. The shift linkage can break at the base of the shifter, but the fix isn't too difficult if you bring a spare part with you.
Hopefully the GT3 will accompany me to a DE event at Mid-Ohio this coming weekend.
05-13-2013 | 03:55 PM
#114
7th Gear
Joined: Jul 2008
Posts: 7
Likes: 0
From: Clarksburg,Ontario Canada
Attention Canadian GT2/GT3/Turbo (Mezger engine) Owners
I just spoke with an agent at Transport Canada at 1-800-333-0510. They were interested in taking in the details of these Porsche Mezger engine cooling system failures. You can also access them online at Transport Canada by filing a report on their 'Defect Complaint Form"
05-13-2013 | 08:35 PM
#116
Nordschleife Master
Joined: Dec 2009
Posts: 5,929
Likes: 22
From: Limehouse, ON
And unfortunately the Turbo was running with coolant, which caused a long shut down for the clean up, unlike with Martin, where we hardly skipped a beat.
Isn't it amazing 
I've been told the same thing many times, yet, I've also personally been at the track to witness 10 - 15 such events first hand to date... including mine last year.
Access form here: https://wwwapps.tc.gc.ca/Saf-Sec-Sur....aspx?lang=eng
Clicking on "Continue" at bottom of the page takes you to the next step.
I've been told the same thing many times, yet, I've also personally been at the track to witness 10 - 15 such events first hand to date... including mine last year.I just spoke with an agent at Transport Canada at 1-800-333-0510. They were interested in taking in the details of these Porsche Mezger engine cooling system failures. You can also access them online at Transport Canada by filing a report on their 'Defect Complaint Form"
Clicking on "Continue" at bottom of the page takes you to the next step.
05-13-2013 | 10:06 PM
#117
Nordschleife Master
Joined: Dec 2009
Posts: 5,929
Likes: 22
From: Limehouse, ON
Filed report with Transport Canada, in 1000 characters or less 
Issue is common, and seemingly unavoidable: All Mezger engine-powered Porsches built between 99 and 2012 (GT3, GT2, Turbo, Turbo S).
In these engines, coolant/anti-freeze circulates through aluminum castings and rubber hoses. Hoses are clamped onto aluminum sleeves that are inserted into the bores of the castings and held in with adhesive.
PROBLEM: Adhesive eventually fails, which allows the sleeves to "blow" out of the engine, resulting in a sudden loss and spillage of slippery coolant/anti-freeze onto the road surface. This causes an immediate and dangerous loss of traction to any vehicle driving through the spill, including the one spilling the fluid.
This has happened both on and off road during normal driving and high performance driver education (DE), and is well documented. https://rennlist.com/forums/996-gt2-...res-nhtsa.html
SOLUTION: Remove engine from the car to weld or "pin" the sleeves.
In these engines, coolant/anti-freeze circulates through aluminum castings and rubber hoses. Hoses are clamped onto aluminum sleeves that are inserted into the bores of the castings and held in with adhesive.
PROBLEM: Adhesive eventually fails, which allows the sleeves to "blow" out of the engine, resulting in a sudden loss and spillage of slippery coolant/anti-freeze onto the road surface. This causes an immediate and dangerous loss of traction to any vehicle driving through the spill, including the one spilling the fluid.
This has happened both on and off road during normal driving and high performance driver education (DE), and is well documented. https://rennlist.com/forums/996-gt2-...res-nhtsa.html
SOLUTION: Remove engine from the car to weld or "pin" the sleeves.
05-14-2013 | 08:54 AM
#120
Race Car
Joined: Jun 2005
Posts: 4,511
Likes: 48
From: Columbus OH
I've always had the GT3 repaired at a Porsche Dealer and the factory claims there is no problem. They just replaced the "malfunctioning" component!
I've owned this car from new since November 1, 2003. It has 135,000 km on the odometer and the car is now getting every spigot tube fixed properly.
My GT3 has done over 250 track days without any serious problems except the cooling system failures. No oil leaks and the original clutch as well. I did have the rear shocks re-built two years ago. The shift linkage can break at the base of the shifter, but the fix isn't too difficult if you bring a spare part with you.
Hopefully the GT3 will accompany me to a DE event at Mid-Ohio this coming weekend.
I've owned this car from new since November 1, 2003. It has 135,000 km on the odometer and the car is now getting every spigot tube fixed properly.
My GT3 has done over 250 track days without any serious problems except the cooling system failures. No oil leaks and the original clutch as well. I did have the rear shocks re-built two years ago. The shift linkage can break at the base of the shifter, but the fix isn't too difficult if you bring a spare part with you.
Hopefully the GT3 will accompany me to a DE event at Mid-Ohio this coming weekend.