2004 PORSCHE 718 BOXSTER

Typical onset: 40,000-80,000 mi

Symptoms: metallic debris in oil filter, knocking or rattling from engine on cold start, sudden catastrophic engine failure with no warning, check engine light with camshaft correlation codes

Fix: Requires engine removal, complete teardown, IMS bearing replacement (or upgrade to stronger aftermarket unit), and often leads to full engine rebuild if metal contamination has occurred. 25-35 labor hours for preemptive replacement, 40-60 hours if engine damage occurred.

Estimated cost: $4,000-8,000 preemptive, $12,000-18,000 if rebuild needed

Typical onset: 60,000-120,000 mi

Symptoms: blue smoke on startup, excessive oil consumption (1+ quart per 1,000 mi), rough idle when warm, loss of compression on leakdown test, metallic particles in oil

Fix: Caused by cylinder liner design and inadequate lubrication. Requires complete engine teardown, cylinder replating or sleeving, new pistons and rings, often full rebuild. 50-70 labor hours. Some owners opt for used engine swap instead.

Estimated cost: $15,000-25,000 for proper rebuild, $8,000-12,000 for used engine swap

Typical onset: 50,000-100,000 mi

Symptoms: oil pooling under engine after parking, oil spots on garage floor centered under transmission bell housing, oil visible on flywheel housing, burning oil smell when engine hot

Fix: Requires transmission and clutch removal to access seal. Often done during IMS bearing service or clutch replacement to save redundant labor. 12-16 labor hours standalone, 3-5 hours added to clutch job.

Estimated cost: $1,800-3,000 standalone, $300-600 added to clutch replacement

Typical onset: 70,000-120,000 mi

Symptoms: coolant puddles under car, overheating warning light, visible cracks in plastic tank, coolant smell in cabin, steam from engine bay

Fix: Plastic expansion tank becomes brittle and cracks; rubber hoses deteriorate. Replace tank and all coolant hoses as preventive measure. 3-5 labor hours for complete system refresh.

Estimated cost: $800-1,500

Typical onset: 60,000-100,000 mi

Symptoms: clunking when shifting or engaging clutch, excessive vibration at idle, gear lever movement feels vague or notchy, visible torn rubber on mount inspection

Fix: Rubber mounts fatigue from engine torque and heat. Replace both transmission mounts. 2-3 labor hours.

Estimated cost: $500-900

Typical onset: 80,000-130,000 mi

Symptoms: difficulty starting when hot, stumbling or hesitation under acceleration, intermittent stalling, reduced power at high RPM, fuel pressure below spec on testing

Fix: In-tank fuel pump wears out; fuel filter (often neglected) clogs. Requires fuel tank drop. Replace pump, filter, and strainer as assembly. 4-6 labor hours.

Estimated cost: $1,200-1,800

Typical onset: 50,000-90,000 mi

Symptoms: excessive smoke from exhaust, oil consumption without visible leaks, rough idle, oil in intake tubing, check engine light with lean/rich codes

Fix: Diaphragm inside AOS tears, allowing oil into intake manifold and creating vacuum leaks. Replace AOS unit and associated hoses. 3-4 labor hours.

Estimated cost: $800-1,400