Another catastrophic cooling system failure
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Originally Posted by pwdrhound
You can send your manifolds to BBI and they will remove, clean, and weld the fittings to you. Fedex is your friend...
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I haven't suffered the water pipe failure yet, but one of the first things I did after getting my car was track down as used parts the four housings with water pipes that could fail and get the fittings welded, so I've got all the parts ready to install if and when the day ever comes that my engine springs a water pipe leak. I'm currently not doing track events, so I can't see dropping the engine (and the $3K - $4K until I actually need to). The most common failure is the small pipe under the alternator that as a temperature sensor in it (first photo below).
FWIW, I spent hours reading all of the threads on this topic, including reading all of the materials submitted by Porsche to the NHTSA when they investigated this problem. I concluded that welding was the best way to go; YMMV.
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FWIW, I spent hours reading all of the threads on this topic, including reading all of the materials submitted by Porsche to the NHTSA when they investigated this problem. I concluded that welding was the best way to go; YMMV.
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Last edited by spooltime; Sep 24, 2018 at 01:00 PM.
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The glues we used have such a massive shear strength you could lift the car on one fitting, if its glued and pinned it cant leak, get a pinhole in the weld and you will be pulling and stripping the motor again !!!
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I know there's a lot of debate on this, but if you can believe the data that Porsche submitted to the NHTSA, the failure rate is actually very low. We hear about most that fail on the forums, but never about the thousands that are still just fine after over a decade of use.
I'm sure I'll get it done eventually, and hopefully before one actually does fail, but I've spent my available car project funding on some other go fast mods and correct maintenance deferred by the PO. Coolant pipes are still about three or four items down the list.
I'm sure I'll get it done eventually, and hopefully before one actually does fail, but I've spent my available car project funding on some other go fast mods and correct maintenance deferred by the PO. Coolant pipes are still about three or four items down the list.
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I know there's a lot of debate on this, but if you can believe the data that Porsche submitted to the NHTSA, the failure rate is actually very low. We hear about most that fail on the forums, but never about the thousands that are still just fine after over a decade of use.
I'm sure I'll get it done eventually, and hopefully before one actually does fail, but I've spent my available car project funding on some other go fast mods and correct maintenance deferred by the PO. Coolant pipes are still about three or four items down the list.
I'm sure I'll get it done eventually, and hopefully before one actually does fail, but I've spent my available car project funding on some other go fast mods and correct maintenance deferred by the PO. Coolant pipes are still about three or four items down the list.
An issue overblown by Internet postings? Naw, that never happens!
I don't know about that, I was able to pull a few of mine out with light force pulling with a pliers. It's really not good. If it does go most of the wrecks I've heard of involving this issue is other cars slipping and crashing behind the 996. 
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Originally Posted by spooltime
I haven't suffered the water pipe failure yet, but one of the first things I did after getting my car was track down as used parts the four housings with water pipes that could fail and get the fittings welded, so I've got all the parts ready to install if and when the day ever comes that my engine springs a water pipe leak. I'm currently not doing track events, so I can't see dropping the engine (and the $3K - $4K until I actually need to). The most common failure is the small pipe under the alternator that as a temperature sensor in it (first photo below).
FWIW, I spent hours reading all of the threads on this topic, including reading all of the materials submitted by Porsche to the NHTSA when they investigated this problem. I concluded that welding was the best way to go; YMMV.
FWIW, I spent hours reading all of the threads on this topic, including reading all of the materials submitted by Porsche to the NHTSA when they investigated this problem. I concluded that welding was the best way to go; YMMV.
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I'd love a parts list to purchase and be prepared myself! If I could do it ahead of time I might consider welding but pinning with a good epoxy is good enough IMO. If the fitting cannot move the seal is going to be fine. There are supposed to be better materials than jbweld for this and knurling seems key!
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May I suggest something, If you go the welding route try to do a good leak check while the engine is out. It is not too difficult to fabricate caps and pressurized the coolant system. I had to go back to the welder three times because of the difficulty of welding the casting with so much impurities.... I started a thread in 2012 about my first engine removal and coolant pipes welding and on page 7 you will see how I did the pressure test on the ground.....Hope this help!
https://www.6speedonline.com/forums/...ts-needed.html
https://www.6speedonline.com/forums/...ts-needed.html