09 GT AWD - leaky PTO(transfer case)

[PlayU18]

I'm going to jump in on this conversation if that is ok with you guys.

We have a 2010 Grand Touring AWD with 34k miles that we purchased used 15 months ago. My wife noticed a strange smell last Friday on her way home from work and asked me to take it for a ride. I don't know squat about cars, but I took it for a ride and noticed the strong burning oil smell, especially when stopped at a light and then accelerating. No visible fluids under the car (or anywhere else for that matter). Took it to a dealer Saturday morning and had them go for a ride with me. Mechanic smelled it also, and immediately said it was transfer case gear oil, probably from a small leak. Said he would order new seals on Monday and call me when they are in. Also said it would be fine to drive it for now.

Well, today my wife noticed something funny happening in reverse, and asked me to drive it again. On three separate occasions, very noticeable slipping of the transmission in reverse. Put it in reverse and press on the accelerator and got nothing but a revving engine, then it would catch and the car would jerk back. Stronger smell this evening than what is was before, even seeping into our house form the garage. So, after panicking and finding this thread, I went out to take a look for fluid, and I think I may have you all beat (although no pics yet because it is dark out). We have lots of thick fluid all over our driveway, including several drips on the way up. And of course more in the garage, and I can see it on various parts under the car now, similar to the pics posted here previously.

My question is...does anyone know if it would still be safe to drive (considering the transmission slipping issue), if even for just a trip to the dealer, or should I get a tow? Also, could a bad transfer case lead to a ruined transmission, or would a new transfer case fix the slipping transmission issue?

Thankfully I am still under warranty, but I want to get it fixed right the first time, even if it means a new transmission along with a transfer case.

Thanks in advance for any replies.

 

[2007cx9]

Once you lose any oil the damage starts and has started already. It is basically self destructing. The transfer case that is... My guess is that the TC is seizing and when it breaks loose you lunge forward (or backward for that matter). Luckily you can get it fixed under warranty.

oh and another from up north, low temps....

 

[PlayU18]

Yep, this all started last Friday when it was cold and we had a small dusting of snow, possibly just enough to make the roads a little slick.

An update to my situation...I called my dealership this morning and explained everything to them. They suggested not driving it again based on the series of events that I had been through. So, we set up a Monday appointment, and Mazda Road Side Assistance is providing a free tow to the dealership Monday morning. I will post updates when available.

 

[dsc888]

Good luck and keep us all posted. The fact that you have a 2010 and it's doing this scares me a bit. I have a 2011 GT AWD and got it with the hope that all the BUGS have been worked out. But at least Mazda is on top of all this and it's an easy and free fix.

 

[PlayU18]

Yeah, sort of shocked that this is happening on a 2010 with so few miles. Even more shocked to see the various other accounts of near identical situations with CX-9's. Makes me think it is just a matter of time with all of them. This is my first Mazda since a 1993 MX-6 back in college (family really likes Nissans), and it is not leaving a great taste in my mouth. I have had two other dealings with this dealership in the past, and they didn't go well, so i am anxious to see how they handle this one. They don't have a great service reputation in this area. I can truly see them trying to find a way out of it, even though the bumper to bumper still has a few months/miles left, and the powertrain still a couple of years. We will see. Crossing my fingers it goes smoothly, even if I am without the car for a while.

On a different note, anyone have any good suggestions for removing thick oil/gunk stains from my driveway and garage in cold weather? This stuff is thicker than old paint, and just smeared when I tried to wipe it up off of my painted garage floor.

 

[HOLOHOLO]

Do we have any clarity on the cause of this failure?

Is it bad seal leading to dry parts and eventual component failure?
A fluid heating or cooling problem? (Cold starts causing wear)
A gearing part or actuator failure?
Something else?

If the transmission fluid is shared with the TC, won't these issues show up with low dipstick readings? Won't tranny parts be acting up and failing as well?

There have been enough of these that there should be breadcrumb trail to follow, and surely Mazda knows.

 

[2007cx9]

The transmission does NOT SHARE anything with the Transfer case. The transfer case is a gear box filled with gear oil. What happens is that something makes these overheat and/or get too pressurized and it starts barfing the oil out of the vent on top of the TC. The oil then drips down all over the TC and finally on the ground making it hard to tell just where it is coming from.

Here is a treasure trove of info:
http://www.fordedgeforum.com/topic/10914-ptu-leak-failures/#entry89270

Yes, the Edge shares the same setup. Its the exact same part number for the TC.

We just got ours back having the TC replaced a second time. After 85K we are on our 2nd replacement. The dealer here gave us one heck of a deal IMO. they did it for $950. It was 650 for the TC and 300 for labor.

They even let me keep the old one. I'll post some pics tomorrow.

The only way to get these to stop failing is to devise some sort of maintenance by either sucking out the old oil and putting in new, or installing some sort of drain plug which would make it VERY simple.

The good news is that the dealers are waking up and might be putting together some sort of maintenance item for it. They might be changing the oil in them for around $100 or so. Well worth it if they do. This is just word of mouth and I can't confirm any of it.

The thing is, these are far from maintenance free. They are just like any other gearbox and need maintenance and regular fluid change intervals. The problem is that there's no way to service them unless you have a drain plug or some creative tubing and pump. I honestly don't know what they were thinking when they went with this. Maybe its the supplier's fault and promised the impossible. who knows?

 

[2007cx9]

Here are some pics of the TC. This gives you a good idea of where the oil pukes out directly on top of the unit.

...

 

[HOLOHOLO]

Outstanding! Can't wait for the forensic autopsy photos. (popcorn)

I enjoyed that ford teardown thread.

 

[table5511]

Ford parts suck.