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Stalling Car - bad alternator?
#1

A week ago - I took the battery tender off of my car - and was driving it down to my trusty Porsche mechanic to give it's yearly oil change and state inspection.

When I started up the car - she turned right over and I gave it a couple of pumps of gas and noticed that the tiptronic light was on (but I was not in tip mode..)... . I let it idle for a bit and it stalled (which is normal for a car that has been sitting for the winter months). Turned the key - turned right over.. the tip mode light did not go back on so I put it in drive and out of the driveway I went.

Left my street, everything was going good - got on to the main road - stopped at a light and it started to chug. then stall. Turned the key -- reved the engine while in park (to get some gas flowing through the engine)...put it in drive when the light turned green. Drove another 200 feet to the next light and the car started to chug and stall again. Started it back up, rev the engine a bit drop it in drive - but when I hit the gas pedal the car would chug/start to stall - so now I would go back into neutral - rev the engine and there would be NO chugging or stalling - only when I put it back into drive. As the car would stall I would put it in neutral to restart (and repeat the process).

The car stalled about 5-6 times --- one time I did notice the tiptronic light back on.. so I said (the car must think I'm in tip mode - let me put it in tip mode then back into automatic) that didn't help. I noticed that the car would not stall when it was in drive - Only when I would apply gas - so since this was 8:30am I decided to put the car in drive and let it "roll" to the mechanic (only about 2 miles away) - however there were about 4 more lights to go on this main drag. I put the car into 3rd gear and creeped there - applying as little gas as possible.

I told the mechanic about the issue (stalling, tip light going on "sometimes", etc) He said he would have a look later. The car was idoling nicely outside, so he said to turn it off and he would call me later. He called me back up and said - you battery is dead when I went to start your car. I said - you replaced that battery last year, and it has been on a battery tender all winter long... I did tell him that I had to start the car 5-6 times over a 10 minute period. He said he will charge it and test it.

Called me back later that day and said the alternator is dead! (the car only had 70K miles on it). He said it was unusual for a car of this mileage to have a dead alternator - but it could happen. I said - replace it... maybe that is what caused the stalling - not enough electrical to run the auto trans.

He replaced the alternator this week (took a couple of days to get the part) - he test drove the car - brought it home one night - and I was sending my wife over the pick up the car today.

He calls me this morning and says not to pick up the car! the alternator is dead.. he was pissed (not at me) but at Bosch - and said that they must have sent him a bad part, and he would get another one and replace.

So I figured I would tell my tale and see if anyone here had any input on this issue?

- I replaced the DIM relay about 2 years ago - first thing I did when I bought the car (I keep the old one in the glove box JIC)

- After some research I found out that if you start the car in neutral the "tip warning light" will not go on -- so that is why the light would go on only sometimes during my stall / restart.

- I did notice that the car sometimes would crank over very slowly. - even after I drove it for a long distance, parked the car, and then tried to restart (50% of the time). When I bought the car 3 yrs ago the guy said he put in a new battery because it was sitting for a while.. last year I told my mechanic about the slow cranking - and he told me that the battery that was in the car was too small, so last year he put in the right size battery. Even after the replacement it would crank over slowly. Could the alternator have been dying all along

- I only drive this car on the weekends - in the warmer months. Last year in NY was a cold and rainy summer ... so the car did not get much road time.

Thanks guys for your input / help
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#2

When I bought my car at 70k or so it had a Porsche rebuilt alternator in it. I ended up replacing that one with another Bosch at around 90k. They can go bad..
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Current:
2016 Cayman S
Former:
94 968 Cab 6 Spd. Black/Cashmere D1R SC
86.5 928 Garnet Red Metallic
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#3

i'd say it was a dead short in the battery circuit - either a dead cell, or a bad main ground - i would hydrometer check the battery, and clean and tighten the main connections - do not assume they are good by visual inspection
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94 Midnight Metallic Blue Cab Porsche 968 w/deviating cashmere/black interior and WAY too many mods to list - thanks to eric for creating www.968forums.com



"It isn't nearly as expensive to do it right as it is to do it wrong."
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#4

My mechanic said that he cleaned all the connections - even the one from the battery to the alternator. Just seems odd that the "new" alternator is dead again.
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#5

could be a cell in the battery - the plates may be touching, creating a short - it happens - hydrometer check it

make sure he cleaned the ground connection at the chassis - that is the problem child
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94 Midnight Metallic Blue Cab Porsche 968 w/deviating cashmere/black interior and WAY too many mods to list - thanks to eric for creating www.968forums.com



"It isn't nearly as expensive to do it right as it is to do it wrong."
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#6

My alternator failed last month. It was the original, 16 years and 150K miles. The car ran on the battery until there wasn't sifficent current to provide a spark at which point the engine shut down. As soon as the alternator quit, the volt meter went to zero, an indication that I was not getting any charge to the battery. I kept driving to see if I could get the car back to the house. Didn't make it. After sitting over night the car started, although it was misfiring. the battery had just enough juice for me to position the car for the tow truck.
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#7




Just spoke to him - he was able to get another rebuilt to put in. He verified that the first thing he checked was the ground connection, and that he did run a check on the battery.

Keep the ideas coming.

He did say that he replaced a 928 alternator a while back and that like mine, the thing died after 10 miles. He said that he is finding that you can't be sure where these places are sourcing their parts from (China seems to be the culprit - to keep costs low). This guy is a good quality Porsche / Audi specialist.. and is a consultant at BMW North America.
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#8

It may not be the alternator that died right away but the voltage regulator.
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Current:
2016 Cayman S
Former:
94 968 Cab 6 Spd. Black/Cashmere D1R SC
86.5 928 Garnet Red Metallic
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#9

thanks for the input - I am passing along all your input. the alternator was replaced and the car seems to be running fine now... He will keep it for a couple of days and drive it around to see if anything unusual happens again
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#10

"thanks for the input - I am passing along all your input. the alternator was replaced and the car seems to be running fine now... He will keep it for a couple of days and drive it around to see if anything unusual happens again"


I'd like to drive it around for a few days too...especially this weekend.... [img]style_emoticons/<#EMO_DIR#>/laugh.gif[/img]

Jay
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#11

Here's an update ..

I'm glad he kept it for a couple of days (1 week). He went back to test the voltage a couple of day later and noticed it was low. As a stroke of luck he happened to move one of the battery cables as he was testing the voltage through the firewall and it spiked... he went back to the battery terminal and it was low...

Anyways - --- it was a bad battery cable/ terminal connection. This was the cable that is crimped onto the terminal connector - the crimp must have went bad and was not sending out the proper voltage. the terminal was nice and tight, but the internal connection in the cable went bad / was not crimped properly. This car has been babied in a heated garage all it's life - and the only snow / rain it has seen has been out the garage window - so there was no corrosion / rust to be found.

Fluke thing mixed with a bit of luck for him to find the problem by bumping the cable at exactly the right moment when the car was acting up. He said he NEVER would have thought about the cable, no indication of it being bad, loose, or neglected. Tested the battery etc and was running out of ideas

I'm happy to pick the car up tomorrow.
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