I am in Texas also and considering using UFO. Have intermix problem after replacing oil cooler that broke. Drove 250 miles and now intermix again. What is turn around time from UFO to get your cylinder head back? Do they actually fix the crack, or do they manufacture a new head through a machine shop? Can you refer me to the other happy TX customer?

 

does thie intermix happen on all 996s, or was this issue ever resolved in later model years?

 

I have had a couple of mechanics say that is was fixed in 2003. Prior to that 1997-2002 996 and boxster number 1 cylinder crack in the exact same place is very common.

 

Please quantify "very common".
I have not found provable, significant data on this.

 

Txporsche

I had an intermix from a cracked head. Cylinder #1, inner exhaust valve seat, then runs down the spark plug tube. I can tell you that I have worked with 8+ other owners since I fixed mine that had cracks in the exact same place. And when I was looking for a used head I checked 5+ used heads. all had cracks in the same spot. Some came from cars that had not yet intermixed, but they were showing the start of cracks in the same spot. I found a place called Costa Mesa R&D, owned by John Edwards (www.engine-machining.com that had a lot of experience in fixing these cracks. As for how common this crack is when I called them and said I had a cracked head on my 996, before I could even say where it was cracked, John said, sure, the #1 cylinder head at the inner exhaust valve seat. I asked him how he knew and he said "that's where they all crack."

In any case it was $500 to repair the crack and do a valve job on that side. I did the R&R myself, spent 20+ hours and about $700 in other parts. I now have almost 10,000 miles since the fix and the car is running strong.

I would recommend Costa Mesa for the crack repair.

Is this crack provable or significant, well Porsche will certainly never say, but it does seem to be pretty common.

++++

 

I had a lengthy email exchange with Jake Raby recently. My engine is solid, but just doing a little due diligence in case big problems were to ever come up.

Man, this guy really knows his stuff, but you get what you pay for: for a complete rebuild with one year warranty, addressing/correcting all known weak points of the 996 engine it would cost more than another 99-01 996.

Still wondering/hoping that UFO is a solid shop. Because of geography, among other things.

 

I am the guy Tim flew out and retorqued and tuned at Rennsport. I now have 20,000 trouble free miles on an engine that runs harder then stock and is as I can see bullet proof. I have a 996 C4 and has been the most maintenance free car since sending to UFO, They really know what they are doing and are easy to talk to. We spend a lot of money on these cars expecting to get the same value back it was sad how Porsche turned their backs on 996 owners knowing the issues inherent in these engines. They should have all been recalled and the fixes UFO does done to every engine.

 

UFO Motorsports built my motor in 2010. Its now going on 3 yrs 30,000 miles+ .

Im still extremely happy !!!!!

I drive it ( HARD ) everyday in Las Vegas 110 degree weather in the summer and 30 degree weather in the winter.

Not one issue to report !

 

I just posted on my new UFO Motorsport 3.4 rebuild. You can find my comments by just typing in UFO Motorsport. Tim did the work there and I just drove it back from SoCal to my home north of SF. Amazing! Details are in my other post. But I am telling you flat out, this man knows his stuff and keeps the costs in line, period. My car has NEVER performed or sounded this good since I bought it with only 14,000 miles on it originally. Now it has 68,000 and it is a '99 996 Carrera, first out of the shoot for Porsche. Its Achilles Heel elements have been replaced with updated parts and it runs like a top! Nice going Tim!!

 

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