2004 Porsche 911 Carrera

Defect. Ohlins USA, Inc (Ohlins) is recalling certain Front Struts, part number POS 5N20. These struts were sold as part of Ohlins strut kits part number POZ MN02, intended for installation on 1999-2005 Porsche 911 Carrera 4 and 4S (generation 996), and 2001-2006 Porsche 911 Turbo / Turbo S (generation 996) and kit part number POZ MN05, intended for installation on 2005-2012 Porsche 911 Carrera 4 and 4S (generation 997), and 2006-2013 Porsche 911 Turbo / Turbo S (generation 997). The pin of the strut may experience excessive stress during maximum steering, possibly resulting breakage of the pin.

Risk. If the pin fails, it will cause separation of the strut from the vehicle, affecting vehicle control and increasing the risk of a crash.

Remedy. Ohlins will notify owners, and dealers will request the return of all unsold kits containing the subject part from dealer/distributor inventory for a full refund. All owners who purchased one of the kits (POZ MN02 or POZ MN05) will receive replacement front struts (POS 5N20 or POS 5N21 - These parts are interchangeable), along with new top mount interface solutions, free of charge. The recall began December 22, 2020. Owners may contact Ohlins customer service at 1-800-336-9029.

The contact owns a 2004 Porsche 911. The contact stated while driving approximately 45 MPH he heard a loud creaking sound coming from the front-end. The contact stated that he was entering the highway and the sound became louder while speeding to merge. The contact stated that after driving over some slight imperfections in the roadway, the front-end started pulling to the left and right with force. The contact stated that extra effort was needed to keep the vehicle in the lane. The contact stated no warning lights were illuminated. The contact exited the highway and drove the vehicle to his residence. The vehicle had not been taken to a dealer or independent mechanic to be diagnosed or repaired. The manufacturer had not been informed of the failure. The failure mileage was approximately 106,000.

TL* THE CONTACT OWNS A 2004 PORSCHE 911 CARRERA. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 65 MPH, THE ENGINE STALLED WITHOUT WARNING. THE VEHICLE WAS SHIFTED INTO NEUTRAL AND FAILED TO RESTART AFTER MULTIPLE ATTEMPTS. THE VEHICLE WAS TOWED TO THE DEALER FOR DIAGNOSTIC TESTING, WHO INFORMED THE CONTACT THAT THE INTERMEDIATE SHAFT (IMS) FAILED, WHICH CAUSED THE ENGINE TO STALL. THE VEHICLE WAS REPAIRED BUT THE FAILURE RECURRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 28,000. THE VIN WAS UNAVAILABLE.

TL* THE CONTACT OWNS A 2004 PORSCHE 911 CARRERA 4S. THE CONTACT WAS DRIVING 25 MPH AND TAPPED THE BRAKES TO DISENGAGE THE CRUISE CONTROL BUT INSTEAD OF THE VEHICLE DECELERATING, THE VEHICLE ABNORMALLY ACCELERATED AND CRASHED INTO A PRECEDING VEHICLE. THE AIRBAG ALSO FAILED TO DEPLOY. THE VEHICLE WAS TOWED TO THE DEALER FOR DIAGNOSIS. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE MILEAGE WAS 57,000. THE VIN WAS NOT AVAILABLE. UPDATED 8/2/12 *CN THE CONSUMER STATED THE VEHICLE WAS TOTALED. A TECHNICIAN DOWNLOADED THE DATA FROM THE VEHICLE'S ENGINE MANAGEMENT SYSTEM TO DETERMINE THE ROLE OF ANY VEHICLE EQUIPMENT MALFUNCTION IN THE ACCIDENT. PORSCHE OF ARLINGTON, THE DEALER, DELIVERED THE DOWNLOADED DATA TO PORSCHE NA, WHERE THE DATA IS ANALYZED. PORSCHE STATED THAT ANY DOCUMENTATION OF PORSCHE'S INVESTIGATION AND ANALYSIS OF THE INCIDENT WAS PROPRIETARY. THE CONSUMER WAS GIVEN TWO CITATIONS FOR VEHICLE NEGLIGENCE AND INTENDS TO CONTEST THEM BOTH. THE CONSUMER NEEDS ENGINE MANAGEMENT SYSTEM DATA TO DO SO. UPDATED 08/06/2012 *JS

CATASTROPHIC ENGINE FAILURE OF 2004 PORSCHE 911 4S W/O WARNING. WELL DOCUMENTED EARLY VERSION OF MODEL 996 INTERMEDIATE SHAFT FAILURE REQUIRING COMPLETE ENGINE REPLACEMENT. KNOWN PRODUCT DEFECT SUBSEQUENTLY CORRECTED IN LATER VERSIONS. NO NOTIFICATION BY MANUFACTURER OR DISTRIBUTOR TO CONSUMERS. HAZARDOUS AND COSTLY MAJOR PRODUCT DEFECT. *TR

THE CONTACT OWNS A 2004, PORSCHE, 911 CARRERA. THE CONTACT STATED HIS ENGINE HAD TO BE REPLACE DUE TO THE INTERMITTEN SHAFT FAILURE. CONTACT STATED HE WAS DRIVING AT 55MPH WHEN HE STARTED TO PRESS THE ACCELERATOR PEDAL AND THE VEHICLE ENGINE STARTED TO SLOW DOWN AND WOULD NOT RESPOND. CONTACT THEN STARTED TO EXIT OF F THE HIGHWAY AND DOING SO ALL THE LIGHTS ON THE INSTRUMENT PANEL STARTED COMING ON. CONTACT DRIVE THE VEHICLE TO THE DEALER AND THEY STATED THE INTERMITTEN SHAFT FAILED AND THEY WILL BE REPAIRING THE VEHICLE. THE FAILURE MILEAGE WAS 9,700

AIRBAGS FAILED TO OPERATE. *TR

DT: THE CONSUMER STATED THAT THE 2004 PORSCHE 911 CARRERA STALLED WHILE DRIVING 10-20 MPH. THE VEHICLE HAS BEEN HAVING PROBLEM FOR OVER A YEAR. THE VEHICLE WAS TAKEN TO THE DEALERSHIP SEVERAL TIMES. THE DEALER COULD NOT FIND THE CAUSE OF THE PROBLEM. THE DEALER CHANGED THE SPARK PLUGS, BUT THE CODE SHOWED THAT CYLINDER SIX WAS FAULTY. THE PROBLEM SEEMED TO BE INTERMITTENT. THE DEALER HAS HAD THE VEHICLE FOR OVER TEN MONTHS. THE MANUFACTURER HAS BEEN CONTACTED, AND THEY PUT THE VEHICLE IN DIAGNOSTIC TESTING, AND THE PROBLEM HAS NOT SHOWN UP WITH ANY EXPLANATION. THE MANUFACTURER HAS ATTEMPTED TO FIX THE VEHICLE. THE PROBLEM WAS STILL UNEXPLAINABLE. *AK