Transfer Case Discussion. My one needs a refurb

[wian]

De Ja vu!
On the 2nd last service, did another engine mount, and they found a leaking transfer case.
On the most recent service a week ago, leaking transfer case still, but leak very minor, oil level still at max since previous service, and oil quality still ok.
The transfer case noise is giving me grief though.
I have taken the car to the same Mazda dealer since brand new, and now they are basically wiping me like a dirty .... You work it out.
they 'couldn't replicate the fault', then when I took a tech for a drive, he couldn't tell me if the whine was from the gearbox, transfer case or diff.
After the test drive he spoke with the foreman, then the lovely service assistant kkindly advised that further diagnosis time would be required, but that the fault was only replicated under conditions that were outside the normal operating conditions of the car, and that as such, their techs are not allowed to replicate those conditions on the road.....
So, according to Mazda, you shouldn't use 40% throttle or more when doing a hill start!
Not really sure where to now. There is a noise that isn't normal, and want a diagnosis and quote to repair. In the words of Clarkson....how hard can it be?
Whine just noticed very faintly n 2nd gear today, so I guess that at least rules out gearbox right?

Hi - I hope for your sake it isnt the beginnings of a rooted transfer case like mine ! The noise will get progressively worse as time goes on . If the bearing fails on the main shaft in the transfer case, it will root all the compontentry in the case and it will shatter the teeth.

I finally got my one fixed ( $4000.00 and 3 months later ) $2k in parts from Mazda and $2k to take it out , put it back together etc Just absolutely ridiculous !!

Just a word of warning to all you guys with the 4WD mazda 6 MPS - Make sure you get the oil in the case checked every 10,000km, and replace it every 30,000 km minimum !!! Even though in the service schedule says it never has to be changed !!! YES - can you believe that - in their own manual it says it never has to be changed ! Stupid Idiots !

More Bad News - The gearbox specialist i had mine repaired at said the parts in the transfer case for the 6 MPS are under engineered. They should have been build stronger for the car in his opinion. Apparently they are having all sorts of issues with the transfer case overseas also....

As for Mazda customer service - I wrote a 4 page letter and the bastards didnt want to know me - They said because the car has done 150,000km its not their problem ., They wrote me a 1/2 page generic letter that didnt answer any of my questions that i put to them

Anyone know the details to contact customer complaints at Mazda Japan ? i feel like sending the letter to them as the bastards in australia couldnt care less !!!

Good Luck Guys and i pray it doesnt happen to your car.....

[12tre]

Hi - I hope for your sake it isnt the beginnings of a rooted transfer case like mine ! The noise will get progressively worse as time goes on . If the bearing fails on the main shaft in the transfer case, it will root all the compontentry in the case and it will shatter the teeth.

I finally got my one fixed ( $4000.00 and 3 months later ) $2k in parts from Mazda and $2k to take it out , put it back together etc Just absolutely ridiculous !!

Just a word of warning to all you guys with the 4WD mazda 6 MPS - Make sure you get the oil in the case checked every 10,000km, and replace it every 30,000 km minimum !!! Even though in the service schedule says it never has to be changed !!! YES - can you believe that - in their own manual it says it never has to be changed ! Stupid Idiots !

More Bad News - The gearbox specialist i had mine repaired at said the parts in the transfer case for the 6 MPS are under engineered. They should have been build stronger for the car in his opinion. Apparently they are having all sorts of issues with the transfer case overseas also....

As for Mazda customer service - I wrote a 4 page letter and the bastards didnt want to know me - They said because the car has done 150,000km its not their problem ., They wrote me a 1/2 page generic letter that didnt answer any of my questions that i put to them

Anyone know the details to contact customer complaints at Mazda Japan ? i feel like sending the letter to them as the bastards in australia couldnt care less !!!

Good Luck Guys and i pray it doesnt happen to your car.....

Well, after all that - we have a winner!
The car has been to the MAZDA dealer for the last 3 services (on distance rather than time as I drive high klms). All 3 I specifically identified the problem noise. Prior to the 3rd service I said it had to be engine mount, so I asked them to order one in as I was sure it would have to be replaced. The did the service and said there was nothing wrong with the engine mount I made them order.
I asked if they checked all the other engine, gearbox and transfer case mounts, to which I was told "They would have checked them all". So I left, expecting to be up for a gearbox and/or transfer case rebuild sooner rather than later.
1 month later I had the car in for 4 new tyres, and after fitting and balance, one of the fitters took the car for a lap around the block.
On his return, he lifted the bonnet and within 10 seconds said "Hey Boss, the engine mount on this is f**ked". Without removing any plastic or any tools other than a torch, he showed me the damaged & leaking mount under the battery.
Anyhoo, I told him about my wonderful experience with Mazda, and he spoke to a mate in Mazda to check if it could be claimed on warranty (unfortunately not - twas the other one that's been done a few times).
Turns out the tyre mob have a workshop as well.
I dropped the car in one morning, they inspected and also found the gearbox mount to be in 2 pieces (explains a lot). Ordered both parts (2 different dealers as no Brisbane dealer had both parts), fitted and finished by 4PM the same day. Legend!
It's like a new car. Gear shift was a bit stiff and rubbery initially, but it has worn in nicely now, and it now puts all the power to the ground without fuss, knock, whine, or other concerning noise.
Summary - that MAZDA dealer is NEVER seeing my car again, and NEVER selling me a car again.
The car will spend the rest of its days being serviced by the workshop attached to the tyre shop.
Although I am very tempted to name and shame the dealer, I will bite my tongue for the moment.
If however you are after tyres at a great price, with great service and a workshop that knows what they are doing, let me know.

[Doug_MPS6]

Given the nature of that job I'd lift/drop the entire engine out and check the gearbox as well and it would save all the ginning around trying to get the transfer case out in situ. You can have the engine out in well under 8 hours in a decent shop. The diagnosis sounds kosher. I'm not surprised at the time taken to get parts - they don't blow too many transfer cases and most dealers don't hold big inventories locally, particularly for a car that is no longer produced.

[tims]

@12tre don't get too stressed about Mazda's carry on - I had similar experiences with BMW and when I complained to head office their excuse was that BMW's have over 30,000 moving parts and so they couldn't always work properly. This, after I'd spent over $5,000 in repairs in its 1st year out of its 3 year warranty. They couldn't explain how both Mornington and Oakleigh BMW missed the 3 major oil leaks the car had developed, which were severe enough to produce smoke from under the hood when stopped at the lights!

At the end of the day Mazda make a good car at a good price and I don't know about others but I really struggled to find what to buy after the BMW and ended up with a 2nd hand 6 MPS. ( And I was too bitten to buy another euro $ bucket. )

Glad you are getting somewhere with your issues though!

[Mazda6MPSbrisbane]

Hi guys,

I apoligise in advance if this is the wrong place to post this, new here...

I previously had a transfer case leak which was repaired. 30,000kms after a service the mechanic told me it was back. After further investigation I found that the leak wasn't coming from any of the places I have already seen on this forum but from higher up... After driving a bit I found that it was seeping from the edges of this little cap looking thing?? I have no idea what it is and have looked through all of the manuals that I can find. It can be moved around a little as well (it's not firm in place). It is about 1-2cms in diameter and has a small gasket around it, my gasket looks a little damaged thus the leak.

If anyone could tell me what this thing is I would really appreciate it.

Sorry these are the best pics I could get.