Transfer Case Leak

[azcat]

At about 9800 miles, I took my -7 in for an oil change. They said it had a leak, based on fining oil on the plastic splash thing. Spent two hours cleaning and inspecting. No leak found. Added dye to the oil. I put a piece of cardboard on the garage floor. After about a week, oil spots showed up. I took the card board and the -7 to the dealer. Here's most of the write-up:

"Inspected oil stains on cardboard. No dye was found. Raised vehicle and removed lower engine cover. Using dye light, searched vehicle for oil leaks. No leaks were found. During inspection, did find oil stains on lower rear engine roll mount. Removed mount and bracket and found oil leaking from transfer case. Removed engine cradle, alternator, RH axle, and front catalyst pipe to gain access to transfer case. Removed transfer case and verified oil leaking from transfer case to transaxle seal. Contacted Mazda hotline. Hotline suggested to replace both seals at transaxle side of transfer case. Replaced both seals. Reinstalled transfer case and filled with 1.3 qts of 80w-90 gear lube. During removal of front catalyst pipe, oxygen sensor was stuck in pipe...Replaced front catalyst pipe...Symptom code 76. Damage code 91."

Took'em a week and a half. For the record, this '07 has already had much more work done to it, and spent more time at the dealer, than my '97 Miata.

Additional thought: you'uns with AWD might not want to run it up to 117 mph to see if the governor kicks in (it does). Apparently, the transfer case seals are not as robust as one would like them to be.

 

[mixmasterlove]

good to know, I have been up to about 100

 

[pipsthedog]

Mine has been in twice for a total of 8 days in the shop with exactly the same thing. It needs to go in again but because the seals have to come from Japan, I can't take it in. The first time they replaced both seals. The second time, Mazda tech told them that there might be too much oil in the transfer case, so they took some out. Now it is leaking more than ever. I made the mistake of buying one of the dealer's service loaners with 5000 miles on it. It seems like everyone has driven the bag off it and could have caused the transfer case issue. If the problem isn't solved this time, it is obviously not the seals but the transfer case itself. Maybe the holes are cast/machined properly.

 

[AWmustang]

I doubt there is anything inherently wrong with the design. The same all wheel drive system is used on the Speed6 and that car is capable of 145+.

 

[pipsthedog]

I meant to say that my transfer case's holes were off spec, not imply the design was bad. If it was, I wouldn't have to wait months for the seals to show up from Japan, as they would be hundreds on the shelves to fix other 7's I don't see how I could have at least 3 sets of seals fail in a few hundred kilometers.

 

[azcat]

I doubt there is anything inherently wrong with the design. The same all wheel drive system is used on the Speed6 and that car is capable of 145+.

Yes, but this is a much heavier vehicle, which might put more stress on it.

 

[AWmustang]

A valid point.

 

[offset_98]

huh...score one for the FWD I guess. I read somewhere the Murano had a problem with people sticking its AWD system into "lock" mode and driving upwards of 50mph and blow it out as well.

 

[TheMAN]

seen a few transfer case leaks in ms6's already

 

[RKD12]

I have exactly the same problem. I have 9100 miles on the car. I saw that it had leaked in the garage so I took it in. I was told it was the seals and that they would replace the entire transfer case. I was later informed they decided to repair instead of replace. It was in the shop for 2 weeks. I got it back and immmediately noticed it smelled like it was burning something. I took it back 4 days later and was told it was leaking again, they called me later that day and also said "we think we overfilled it". That's where I am at right now, the manager is driving it home tonight to see if it leaks. So, the saga may continue.......

What are the odds that multiple dealers are "overfilling" it....sounds kinda wierd to me.....

 

[mikey1981]

if this is another across the board prob for this car, like the engine cel, man is that gonna make me one pissed off person, if i even make it to 9k plus. however, at least i know that if my car has another problem its a goner and i get a new one. no more weeks on end waiting for parts with no shipment dates and driving rental cars.

 

[azcat]

I have exactly the same problem. I have 9100 miles on the car. I saw that it had leaked in the garage so I took it in. I was told it was the seals and that they would replace the entire transfer case. I was later informed they decided to repair instead of replace. It was in the shop for 2 weeks. I got it back and immmediately noticed it smelled like it was burning something. I took it back 4 days later and was told it was leaking again, they called me later that day and also said "we think we overfilled it". That's where I am at right now, the manager is driving it home tonight to see if it leaks. So, the saga may continue.......

What are the odds that multiple dealers are "overfilling" it....sounds kinda wierd to me.....

Mine had a serious stink to it, too, but I attribute it to the fact that they had to replace the front catalyst pipe, which probably had something on it. The stink is now gone, there are no leaks on the floor, and all seems well.

And, I got a call today that my new door seals are in; all in all, a good day.

 

[RKD12]

funny that you mention the stink...that's the reason I took it back, I assumed they got something on the exhaust and it would eventually burn off when it didnt I called and they told me to bring it in. That's how they found it was actually leaking again, I didnt see the leak this time, I smelled it!

 

[trees]

my mazdaspeed6 transfer is leaking too

 

[azcat]

No leaks so far, no stink. Going in 7 May for the door seal thing. Hurray!