Cayman Sports Exhaust - valve failure
- Thread starter Motorhead
- Start date
AndrewCS
Active member
Recent inspection whilst in for MoT at the OPC revealed that the nearside muffler valve had failed - seized, thankfully in the `failsafe` open position 
Not totally unexpected given the history with these items and covered under the extended warranty
Also highlighted was that all the exhaust fixings were corroded, although not noted back in October during the six year service. Given that half of the fixings come under the warranted muffler replacement I was offered to change the offside fixings for ~ £300 (including PCGB discount). I declined the offer given that this side`s muffler valve is also likely to fail - seize soon !
The valves are located below the actuator (6) bracket
Not totally unexpected given the history with these items and covered under the extended warranty
Also highlighted was that all the exhaust fixings were corroded, although not noted back in October during the six year service. Given that half of the fixings come under the warranted muffler replacement I was offered to change the offside fixings for ~ £300 (including PCGB discount). I declined the offer given that this side`s muffler valve is also likely to fail - seize soon !
The valves are located below the actuator (6) bracket
Hi Andrew
I understood that silencers (mufflers is American []) were regarded as consumable items.
Are you saying that one silencer is being replaced under the extended warranty?
I understood that silencers (mufflers is American [
]) were regarded as consumable items. Are you saying that one silencer is being replaced under the extended warranty?
When I had my 996 some years ago, I had a sports exhaust fitted at an OPC which came with a two year warranty.
Two years and two months later a valve failed. The actuating arms sheared through corrosion. Yep you guessed it ..... sorry sir its out of warranty !!
I purchased a valve form the OPC and fitted it myself. Pretty straight forward job really as none of the clamps or bolts were corroded.
Good luck.
Two years and two months later a valve failed. The actuating arms sheared through corrosion. Yep you guessed it ..... sorry sir its out of warranty !!
I purchased a valve form the OPC and fitted it myself. Pretty straight forward job really as none of the clamps or bolts were corroded.
Good luck.
Given the racket (lovely sound) mine is now making, I think neither of my valves are working. But as I am currently enjoying the beauty of the south of France it is going to have to wait until I return home before it gets attention.
It does seem a common failure point, on most Porsche models.
) mine is now making, I think neither of my valves are working. But as I am currently enjoying the beauty of the south of France it is going to have to wait until I return home before it gets attention.It does seem a common failure point, on most Porsche models.
Windy_Miller
Guest of the Club
For anyone out of warranty and experiencing PSE operation woes have a read through this thread from the Cayman OC before even considering parting with £2-3k for a complete silencer/muffler.
https://www.caymanoc.com/forums/topic/2122-pse-issues-9872s/
Its primarily (my) 987 focussed, but has a a bit about the 981 in it also.
in short, it seems OPC part catalogues don’t include the pneumatic valve actuators as separately available components for Caymans (thus telling you you need to spend £000s), when actually the equivalent 997 / 991 valve actuators are the same part no. as those fitted on the cayman, and are available to buy separately for ~£100.
go figure
not only is there a Porsche tax, but it would seem there’s also a further Cayman tax…
https://www.caymanoc.com/forums/topic/2122-pse-issues-9872s/
Its primarily (my) 987 focussed, but has a a bit about the 981 in it also.
in short, it seems OPC part catalogues don’t include the pneumatic valve actuators as separately available components for Caymans (thus telling you you need to spend £000s), when actually the equivalent 997 / 991 valve actuators are the same part no. as those fitted on the cayman, and are available to buy separately for ~£100.
go figure
not only is there a Porsche tax, but it would seem there’s also a further Cayman tax…
AndrewCS
Active member
In reply to your in short ...
The picture in post 1 is from a 2013 - 2016 Cayman 981 Model C14 PET catalogue, the vacuum []actuators (6) are noted as 991 111 381 02 and 991 111 385 01 ... I had one replaced under warranty on a 981 Cayman S. The valves are not shown
The 987 (2009 - 2012) Model 987209 PET catalogue shows the valves & actuators but does not itemise them hence no part number
The 2016 981 GT4 Model PET catalogue shows the actuators 991 111 381 02 / 991 111 385 01 but not the valves
Without warranty I would be leaving it in it`s `failed open` state and disconnecting / plugging the vacuum line from the other side, to ensure that it also remained open
The picture in post 1 is from a 2013 - 2016 Cayman 981 Model C14 PET catalogue, the vacuum [
]actuators (6) are noted as 991 111 381 02 and 991 111 385 01 ... I had one replaced under warranty on a 981 Cayman S. The valves are not shown The 987 (2009 - 2012) Model 987209 PET catalogue shows the valves & actuators but does not itemise them hence no part number
The 2016 981 GT4 Model PET catalogue shows the actuators 991 111 381 02 / 991 111 385 01 but not the valves
Without warranty I would be leaving it in it`s `failed open` state and disconnecting / plugging the vacuum line from the other side, to ensure that it also remained open
Windy_Miller
Guest of the Club
The actuators are actually very easy to change - especially on 981s as the bracket they sit on faces the ‘right way’ to access the x3 nuts that secure the actuator to the bracket without needing a triple-jointed wrist and a child-sized hand, not needing to remove the rear bumper.
unless one desperately no longer wanted the option of ‘quiet mode’ from the PSE system theres little reason to not change a failed actuator if you’re comfortable using a small spanner, a pair of snips / junior hacksaw (to remove the hose cleat) and some crimps (to fit a new cleat). for those less inclined to wield tools on their Porkers (and out of warranty) an Indy should be more than capable of this task - it’s literally 3 nuts.
one can certainly save thousands by avoiding replacing an entire silencer / muffler for the want of a ~£100 valve actuator is my principal point.
unless one desperately no longer wanted the option of ‘quiet mode’ from the PSE system theres little reason to not change a failed actuator if you’re comfortable using a small spanner, a pair of snips / junior hacksaw (to remove the hose cleat) and some crimps (to fit a new cleat). for those less inclined to wield tools on their Porkers (and out of warranty) an Indy should be more than capable of this task - it’s literally 3 nuts.
one can certainly save thousands by avoiding replacing an entire silencer / muffler for the want of a ~£100 valve actuator is my principal point.
Hi all
I've had 4 exhaust replacements in 5 years. The valves keep seizing. Anyone ever had a suggestion for a permanent solution from Porsche? Costing me £1,000 a time or an extended warranty to cover this cost... for a part that continuously fails and is clearly not fit for purpose. Dealer can do nothing, Porsche GB won't address. Anyone had any positive experience?
I've had 4 exhaust replacements in 5 years. The valves keep seizing. Anyone ever had a suggestion for a permanent solution from Porsche? Costing me £1,000 a time or an extended warranty to cover this cost... for a part that continuously fails and is clearly not fit for purpose. Dealer can do nothing, Porsche GB won't address. Anyone had any positive experience?
That seems exceptional Paul, even for Porsche actuators. If it is fixed under warranty then this frequency of claim should surely raise questions that the warranty company or Porsche want anwering. However, if the warranty won't cover it, I would be looking for an independent who offers the valve only replacement described by Windy above.
Having said all that, the valves on my 981 have seized up, but the arms are still OK. So 10 minutes with a pair of mole grips, some penetrating fluid and then copperslip has got them back to a functioning state.
Having said all that, the valves on my 981 have seized up, but the arms are still OK. So 10 minutes with a pair of mole grips, some penetrating fluid and then copperslip has got them back to a functioning state.
When I bought my current 981 it was 6 years old and looked immaculate underneath. I walked around underneath with the tech from the selling OPC and asked him about how to protect the PSE valves. He recommended spraying with grease occasionally. In addition to occasionally working the valves manually, for the last 2 years & >10000 miles I have used an aerosol 3-in-1 "anti seize copper grease" (a WD-40 product) which says it operates from -18C to 1100C. The metal components get coated in a coppery film and the lubricant seems to keep the moving parts moving. May not be the ultimate solution but so far so good for me.
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