Cayman Crunching noise

[Carbon]

I have recently noticed a noise coming from my cayman when cursing along in 7th gear, The noise only seems to happen when applying a small mount of throttle. The noise also appears occasionally when the car shift gear between 5th -7th. I have the car booked into the Teeside OPC but wondered if anyone else encounter this before or may know what the issue could be. The noise isn’t very loud and I manage to capture the recording by mounting a mic from the GoPro under the car.

2016 PDK Cayman 2.7 Millage:38K
Noise recording : https://www.flickr.com/photos/156036579@N08/52436417942/in/dateposted-friend/

 

[Motorhead]

I’m afraid that you’re very much on your own when it comes to PDK issues Adam because there’s little that the dealers can do other than to reflash the electronics and change the clutch and transmission oils. I think that the clutch oil should be changed at 6-years/60,000 miles, so that should have been done already on your car, while the transmission oil should be changed at 12-years/12,000 miles.

Teeside will be able to run some diagnostics to see if there are any error codes flagged-up and take appropriate action if that’s possible. Unfortunately Porsche’s position is that the PDK transmission is not repairable and that any significant issue can only be dealt with by a [costly!] full replacement.

Jeff

 

[Carbon]

Hi Jeff

Yes i have head about the horror storied of bad PDK transmission and the potential cost of replacements. I do still have a warranty on the cayman so if it dose turn out to be a gearbox issue i would hope it would be covered under that.

regarding the gear box the car shifts gear perfectly fine with no stutters or issues in all gears and in all modes (sports, sports+) Noise aside on occasion as already mentioned. I haven't ruled out the possibility of a gearbox issue but as the noise happens once a small amount of power is applied. I am assuming this is also the case for the split second of power application from then the car move from one preselected gear to another causing the noise within a gear change. in addition to mention it only ever seems to happen when the car is shifting up gear never down gear.

Im not 100% sure if i have had the clutch or transmission oil changed. The car is due its next service early next year bridging the 6year (clutch oil ) period for a recommended change. However as you mention i may be worthing thinking of having them both done to inspect the old oil and see if it contains things it shouldn't.

 

[keiththo]

I've had a similar noise on my 2015 2.7 Cayman since the car was 2yrs old, I wonder if it's actually the same issue ?

I tried describing it to a technician at my OPC but they didn't notice on a test drive they'd just completed and the car has been test driven many times since in the course of servicing etc without comment.

I have noticed that it occurs only at 1500 RPM but happens in several gears. It's especially audible whilst driving next to a central reservation concrete barrier or in a tunnel as that reflects the sound. For some time I've thought it may be rattle from an exhaust silencer rather than a gearbox/engine issue as it only occurs at the one specific frequency.

I've owned my car from new and fitted PSE a year into ownership. The noise hasn't got worse despite the mileage climbing to 59000

Interesting to hear what Teeside tell you.

Keith

 

[JohnCRS]

Hi Adam. The problem that I had was the clutch pack slipping. This meant that if you applied throttle in a high gear, at low RPM (basically a high torque situation) the clutch pack could be heard graunching. BUT, in my case the clutch slip caused the revs to flare momentarily as you would expect. 60 ish in top on an upward gradient would be the ideal situation. It is difficult to tell from your video but I do not see the revs fluctuating, but the most likely solution Teesside can try is a synchronisation and perhaps a fluid change. At least you do have the warranty so it will be good to find out what they say.

The biggest issue was that this did not trigger any warning lights so 'officially' there was no problem.

However that was 5 years ago and there is more knowledge and experience out there now.

 

[Scrounger]

Show the video to the Technician as he could probably use it for diagnosis.

As mentioned, they'll plug it in for error codes but there's nothing like hard evidence to prove something is wrong. Chances are it wont do it when the Tech drives it.

Dan

 

[Carbon]

Hi all

just an update on what has happened so far..... I managed to take the car to the OPC and let them take a look. With showing Technician the recording and taking the car out for a drive, we managed to narrow the noise down to the exhaust more accurately the back-box/sports exhaust bypass flaps.

So took the car out for two drives, as usual driving to the dealership and on the first drive with the tech the car didn't want to make any noise I could consistently reproduce the day before []. After having it on the ramp and not seeing anything underneath took the car out for a second drive and luckily the issue came back. After a little more poking around and a bit more driving about managed to notice the noise being significantly more present when the sports exhaust is on (exhaust faps open) than off. The end conclusion being an issue with the back-box/sports exhaust bypass flaps. The car is booked back in to have it fixed so we can see if this solves the issue.

@keiththo

It could possibly be a very similar issue, the tech did mention that some time the welds around the exhaust tips can come lose and cause a small rattle or alternatively it being some of the internal baffles coming lose. Dose your cayman Have sport exhaust and dose it make a difference in how loud or frequent the noise occurs?

@JohnCRS

Yes i Believe i remember the car it was your old Cayman R. Luckily the gearbox and clutch seem operate perfectly to be fine. I did test the car placing it in manual mode and giving it a decent amount of throttle in both 6th and 7th, not seeing any sudden jump in the rev counter.

@Scrounger

If i can I'll mostly try and get a recording of the issue to present the OPC, it makes it a little smoother process. Quite often as you mentioned the issue never wants to occur when your at the dealership.

 

[JohnCRS]

Thanks for the update Adam. Great news that it is not the box. My bet would be the baffles in the exhaust which you would of course hear better (worse?) with the valves open. I would have thought if it was the valves themselves you would be able to detect movement in the butterfly valve. Do check in advance that it is covered by the warranty.

 

[keiththo]

@keiththo It could possibly be a very similar issue, the tech did mention that some time the welds around the exhaust tips can come lose and cause a small rattle or alternatively it being some of the internal baffles coming lose. Dose your cayman Have sport exhaust and dose it make a difference in how loud or frequent the noise occurs?

Yes I have PSE which was fitted when the car was a year old. I've not noticed that the noise level is any different with the PSE on or off but it only occurs at 1500 rpm