The air bag warning light is proving to be a real pain. Was suspected of being a dead short in the instrument cluster then the airbag trigger/control unit. A new airbag trigger/control unit was ordered. This was done based on I believe input from a factory support person. The dealer/techs have been in contact with the factory on this problem. Surprisingly the problem is a bit more complicated than I at first suspected. More on this below.
I visited the dealer and picked up the old airbag control unit and took it to the office and removed the circuit board from the enclosure and examined the board under a microscope. A very nice looking circuit board, nicely conformal coated, and with not one sign of any problems.
Not too long after I looked the board over, the SM emailed me the new airbag trigger unit did *not* solve the problem. So I put the old unit back together and returned it. The new unit was not digitally connected to the vehicle so it can go back into stock and the original unit can go back into the car. Whew! The new unit lists for over $800.
Before meeting with the tech, I did some research on airbag warning lights and Boxsters, then went to talk with the tech.
My research found a problem with 2001 and earlier Boxsters and the seat belt connectors. There is a TSB on this. My car was made in late 2001. However, my research turned up that even with cars that were fitted with the new/improved seat belt connectors problems, albeit less common, can occur. And with now over 290K miles and a lot of seat belt couplings/uncouplings under its belt (no pun....) I felt the Boxster might be due for new seat belt buckles/connectors.
The problem is there are no errors from the airbag control unit. This is the complication I spoke of above and why factory support help has been solicited. The light can be extinguished but the light comes right back on. The tech found the driver's side seat belt connector was staying released when the button was pressed down to unlatch the buckle. He replaced this but it didn't help. Based on my research my WAG was a seat belt buckle was probably the cause of the problem, but apparently not. However, I had no problem with the tech replacing this and said if he felt the other connector questionable he could replace that too.
The thinking is back to a short in the instrument cluster. I pointed out there has been no other electrical problems, no fuses blowing, nothing that would even suggest there's an electrical problem. The tech said the short is after the load which won't blow fuses but the airbag control unit is sensitive enough that it detects the short and lights the warning light.
The plan is to remove the instrument cluster. A new one is estimated to cost $2500 and I told the tech I would *not* agree to spending that kind of money to eliminate an airbag warning light with no error codes associated with it. Before I did this I would tape over the light and drive on.
The tech said the unit can be sent out to be rebuilt for $400 plus shipping. I agreed to that. However, before the tech sends the unit out to be rebuilt I think I'll take a look at the unit, take it to the office and let a tech look it over. If the problem is just a short a wire splice or shrink wrap or something may be all that is necessary to resurrect the unit and I can save $400 plus s&h.
So there it is. An update.
I hate "electrical" problems.