powdrhound

997.1/.2Cup and 991.1Cup Mergers used the 997.1GT3/RS/997.2GT3 street intake manifold and are supposedly not susceptible to this. I would be curious what exactly the difference is in the 7.2RS and 4.0RS manifold is that has the flaws.

rafter75

Could all this be avoided by replacing with a Dundon intake?

RAudi Driver

So the question is, did Elliot's car get the recall fix? If not then would Porsche step up and foot the bill? If he did get the recall fix, would Porsche step up and foot the bill? If Porsche did foot the bill, would hey foot it at Sharkwerks?

vma1788

Yeah, the Dundon does not have flaps. It does however make the low end pretty lazy but bumps mid range HP a ton and 1 less thing to worry about. 2 big pros for 1 negligible con.

Elliot- bummer to hear man. How do you know this is what happened without tearing it down?

FLT6SPD

The distributor tube is physically smaller on the 3.6GT3/RS and 3.8GT3, the larger one is on the 3.8RS and 4.0 and mates up to the larger distributor tubes that mount to the heads.

The distributor tube on the cup is 997.110.116.90 on the 3.6 and 3.8GT3 is both 90 or 91, why they stayed with that on the cup is prob the same reason they use restrictor plates on the throttle body, precise horsepower control due to race regulations

RAudi Driver

It sure could but at a cost.

Question is, could it be avoided with the WC-51 recall completed? If I assume ye, then I'm going to assume that Elliot did not get the recall work done to his car, which brings me back to my original question. Will Porsche foot the repair bill?

Vocan

Sounds like the recall work is still not a guaranteed fix based on the original poster of the thread. Seems like he had the recall done and it still failed, though maybe there were other factors at play?

powdrhound

I get the size difference of the distributor tube, just curious what mechanically is different that would make the 91 (RS) valves, or rather the attachment hardware of the valves, susceptible to coming loose and falling apart compared to those used in the 90 distributor tube. I have a 991.1Cup motor that we will be using as a core for an upcoming 4.0 build and we will take a detailed look at the valves and take whatever precautions are necessary to make sure the hardware on these can't come loose. Something as simple as a small tack weld may be in order for peace of mind. I also have a spare 3.8Cup intake (90) in my parts bin and will take it apart when I get a minute to look at what we are dealing with. Again, the hardware may not be representative of the 91 however by the sound of it. Does anyone know what the flapper recall on the 91 intake actually entailed?

FLT6SPD

If you show me yours ill show you mine... I have a new RS/4.0 distributor tube I can take some detailed pics, prob cannot get to it until after memorial day though.

powdrhound

Easy enough. I'll post up the pics this weekend.

EMpunker

How common is this issue? Besides the coolant lines failing, these cars seem to be pretty bullet-proof...?

ilko

That happened to me as well two years ago. The arm that holds the intake butterfly flap broke. A piece of it fell inside cylinder 5, causing catastrophic damage and necessitating a full engine rebuild, totaling over $35K. That was the updated intake that broke, it had been changed during the recall in 2013. Mind you, the newest version of the intake Porsche now sells is a different part number than the recall-updated version. So at some point they've decided that version wasn't good enough...

I fought Porsche long and hard for a year to cover the engine rebuild, since the recalled part failed. I even contacted NHTSA, etc., etc. In the end they did nothing. Really poor customer service.

I am not confident that the newest version of the intake tube is going to be robust over time. So I asked the shop that rebuilt the engine to create special screens on both sides of the intake tube, to catch shrapnel if the arm breaks again:

Elliotw44

Confirmed today my car had WC512 completed in 07/2013. Still need the part number off my cars center section.

RAudi Driver

I don't know if that's a good or bad thing. What's your next more Elliot?

Elliotw44

• Understand the total damage and how much needs to be replaced on my car.
• Understand which part number failed on my car. The starting part number is 997.110.116.90. The latest part number is 997.110.116.95. That will help me understand if my failure is an intermediate revision or the final revision. Given that my car had the WC512 completed, I expect the part on my car to be in the range of 91-95.
  • if it's the final revision, look for an alternative solution like @ilko
  • if intermediate revision, go with the latest revision
• Pay the bill and get the car running again ASAP.
  • I called Sharkwerks about an engine build. The waitlist is out to 2026, which is out of the question given that I don't want the car down for 1.5 years.

It's a fool's goal in my mind to try to get Porsche to pay for this, being that it's so far out of warranty and production. They mostly care about selling the latest and greatest.