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Thread: Transfer Case Discussion. My one needs a refurb

  1. Default Transfer Case Discussion. My one needs a refurb

    Gday Guys

    I am new to this forum. I am glad i found this website....

    I have a 2006 Mazda MPS 6 Speed Manual. Its a totally fantastic car which i bought early 2011.. I havent had one issue ever with the car until last week which i will explain below:

    I first noticed when travelling at 70 - 100km that the car seemed to be running a bit rough. I thought nothing of it thinking that it might need a change of oil as it was due foe its next serivce shortly. All of a sudden a few days later, the car was making this loud grinding noise when the car revs were slowing down as i approached a corner or a traffic light. at this stage i know something was seriously wrong

    i took it to my mechanic and he had a suspicion it was something to do with the driveline... He opened the transfer case sump plug and sadly found a large chunk of metal which he believed was one of the broken bits of teeth off one of the internal parts inside, and the lubricant was a very very dirty colour

    i then took the car to a gearbox and diff specialist here in bayswater melbourne for a second opinion. After 8 hours of labour to pull the bloody transfer case and gearbox out ( Thanks Mazda by the way for such a fantastic accessible design which has cost me 8 hours in labour already ! ) they confirmed that a bearing in the transfer case had blown and the floating chunks of metal from the broken bearing in the transfer case would have most likely caused the chipped teeth off the other internal parts in the case... Luckily the gearbox was ok.

    Anyway, to cut a long story short, its going to take another 8 hours to refurb the transfer case either by getting the parts off mazda which is just a rip off mind you !!! The transfer case in the Mazda 6 MPS is totally unique so you can only use Mazda parts in for the refurb. They cannot be sourced from any other car or from other companies that make similar parts etc...And i need a whole new set of bearings to go with the 3 broken parts, so the parts alone will cost me about $2k and then another 8 hours to put the parts back into the car once refurbed. Mazda Ringwood have told me that my car is the first one they have heard of that has a rooted transfer case which is just wonderful news for me !! So the job is going to cost me around $4k total !!!!!!! ARRRRHGH !!!!

    What i need to know off you forumers is :

    would it take roughly 8 hours to remove the transfer case as i am a bit suspicious that it would take this long?
    Can i access a second hand transfer case in good condition and how much would it cost?
    Can you access transfer cases in good condition from overseas?
    Can you find parts for the transfer case other than buying new ones from Mazda?
    Would it take 8 hours to refurb a transfer case if someone with skills in this area had all the parts needed?

    Any other advice would be appreciated as its a tricky situation i am in


    thanks for your help, and i hope no one else has this happen to their MPS as its been a bloody nightmare !

    cheers
    Last edited by wian; 17-08-2012 at 09:53 PM.

  2. #2
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    I think there is a 6mps in QLD wrecking yard...try gumtree, would be the quickest way out of it and more than likely the cheapest way going about your repair!

  3. Default

    Quote Originally Posted by MPS2NV View Post
    I think there is a 6mps in QLD wrecking yard...try gumtree, would be the quickest way out of it and more than likely the cheapest way going about your repair!
    thanks

    do you know how long it actually takes to remove a transfer case roughly? the gearbox place claimed it took 8 hours, but i am very suspicious?

  4. #4
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    It depends on how they tackled the job, you said they pulled your gearbox out also so 8 hours sounds fair, these cars can be time consuming and alot of little things can eat up time.

  5. Default

    Quote Originally Posted by MPS2NV View Post
    It depends on how they tackled the job, you said they pulled your gearbox out also so 8 hours sounds fair, these cars can be time consuming and alot of little things can eat up time.
    they diagnosed it was the transfer case and not the gearbox initially, so would it take 8 hours to remove just the transfer case without the gearbox?

  6. #6
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    If your car is standard its possible, however if it was found that the oil was contaminated with metal debre it also possible the contamination could enter the gearbox and create future failures. I think they have made right decission so far...
    also depends on what way they went about removing the parts. The transfer can come out seperately but requires the removal of the surrounding parts in order to gain the room required to minipulate the transfercase out of its hole.
    Last edited by MPS2NV; 17-08-2012 at 10:13 PM.

  7. Default

    Mazda can go get F'd as far as i am concerned. Its been 5 weeks now and i still havent got the parts from Japan. Shit house service and they dont want to know about me. I am fuming ! I cant believe for a company like mazda how appaulling the customer service is

  8. #8
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    Default Re: Transfer Case Discussion. My one needs a refurb

    Wow! Spoken to mazda Australia?

    Sent from my GT-I9100 using Tapatalk 2

  9. #9

    Default Transfer Case Discussion. My one needs a refurb

    Quote Originally Posted by wian View Post
    Mazda can go get F'd as far as i am concerned. Its been 5 weeks now and i still havent got the parts from Japan. Shit house service and they dont want to know about me. I am fuming ! I cant believe for a company like mazda how appaulling the customer service is
    Write a letter. Sounds stupid, but when I did, my fuel tank that was ordered six months ago, came in a week


    Peter "SLIXX"

    Snapped by Tangcla - FB Page
    Currently RaydTuned
    Lots of love from 2XS Racing & Dan's Garage Detailing

  10. #10
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    Quote Originally Posted by wian View Post
    Mazda can go get F'd as far as i am concerned. Its been 5 weeks now and i still havent got the parts from Japan. Shit house service and they dont want to know about me. I am fuming ! I cant believe for a company like mazda how appaulling the customer service is
    Getting parts from Japan sucks...

    When I smashed my car just before xmas, they had to order a pair of headlights and 1 headlight washer from Japan... The headlights took 3 months, and the washer took 6 months!

    When I went to Mazda parts myself to get a dipstick tube, they told me they were on back order... 3 month wait...

    Bloody imported cars...

    Chris.
    '05 MPS 6, Liquid Silver Metallic, Leather, Sunroof.

    DashHawk, TurboSmart Dualport, COBB SF SRI and TIP, CPe REM, 2XS Titanium SSP, Coolant bypass,
    Exedy OEM spec clutch, Corksport SS Braided Clutch Line, ROH Mantis 18*7.5+45.

    Growing old is compulsory... Growing up is optional...

  11. #11
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    there is a transfer on ebay for $600 06-07 MazdaSpeed 6 PTU transfer case | eBay

  12. #12
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    Write on their face book page!

  13. #13
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    Has anyone currently got their transfer case out?

  14. Default

    I got my 6MPS serviced yesterday and they told me the transfer case is leaking.. At first I thought not such an issue and pretty quick fix.

    How silly of me! The parts only cost $90 (3 seals) but the labour is gonna be $1000!!! Seems pretty consistent with what is on this forum. They quoted 6-8 hours labour at $130/hr...

    Can anyone tell me what will happen to car if not fixed straight away?

    Also I have now gone through my 2nd drivers side engine mount in 12mths. Is anyone else having same issue with Mazda engine mounts? I know there are after market ones but understand this increases vibration. Already have an exhaust from turbo that gives some resonance and don't really want anymore vibration....

    Sorry if questions already answered on this forum, been a while since I last logged on.

    Cheers

  15. #15
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    Default Re: Transfer Case Discussion. My one needs a refurb

    Motor mounts are notoriously crap on these cars

    As for transfer case, @rayd might be able shed light on cost for transfer case repair?

  16. #16
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    Quote Originally Posted by RED6MPS View Post
    I got my 6MPS serviced yesterday and they told me the transfer case is leaking.. At first I thought not such an issue and pretty quick fix.

    How silly of me! The parts only cost $90 (3 seals) but the labour is gonna be $1000!!! Seems pretty consistent with what is on this forum. They quoted 6-8 hours labour at $130/hr...

    Can anyone tell me what will happen to car if not fixed straight away?
    Quick fix? BWAHAHAHA... I wish...

    6-8 hours is about right, but your hourly rate seems a tad high, is that Mazda rates?

    If not fixed... depends on the severity of the leak... if not leaking badly enough to drip on the ground under the car (without the under cover on) then it probably does not leak enough to be an issue except for the smell, as long as it is topped up regularly (every oil change or so?)... If it is leaving oil on the ground then it probably leaks enough to be an issue... the case does not hold a lot of oil, and is an expensive fix if you destroy it.

    I resealed the case myself while it was out with the clutch being done (there is a thread here somewhere...) and I did not replace the seals in mine, as it was quite obviously leaking from the joint in the case, and 2 of the seals were on back order with mazda anyway...

    No leaks so far!

    Chris
    '05 MPS 6, Liquid Silver Metallic, Leather, Sunroof.

    DashHawk, TurboSmart Dualport, COBB SF SRI and TIP, CPe REM, 2XS Titanium SSP, Coolant bypass,
    Exedy OEM spec clutch, Corksport SS Braided Clutch Line, ROH Mantis 18*7.5+45.

    Growing old is compulsory... Growing up is optional...

  17. Default

    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?

  18. #18

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    i have replaced all mounts in mine to aftermarket after breaking the rear mount, drivers mount (twice), snapped my diff brace and sheared the bolts from my front diff mount... BUT - yet to fix the transfercase leak, hasn't got bad enough yet i dont think :P

    if someone does find a brave soul that kindly fix's the weeping transfer for a good price be sure to let me know

  19. #19
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    Quote Originally Posted by SarcasticOne View Post
    Motor mounts are notoriously crap on these cars
    That is the downside to in-line 4-cylinder engines... no amount of balance shafts and plasticne engine mounts will get rid of the horrid 4-cylinder-tractor-engine buzz, it is an inherent "feature" of the in-line 4 engine layout, flat fours (scooby-doo) do not suffer this, and engines with cylinders numbering more than 4 do not suffer as badly... the more cylinders the merrier really...

    Quote Originally Posted by rayd View Post
    i have replaced all mounts in mine to aftermarket after breaking the rear mount, drivers mount (twice), snapped my diff brace and sheared the bolts from my front diff mount... BUT - yet to fix the transfercase leak, hasn't got bad enough yet i dont think :P

    if someone does find a brave soul that kindly fix's the weeping transfer for a good price be sure to let me know
    Is one of those things that, as long as you keep an eye on it and don't mind the smell, can wait till you are doing a clutch or something isn't it... :P

    Cheers,

    Chris
    '05 MPS 6, Liquid Silver Metallic, Leather, Sunroof.

    DashHawk, TurboSmart Dualport, COBB SF SRI and TIP, CPe REM, 2XS Titanium SSP, Coolant bypass,
    Exedy OEM spec clutch, Corksport SS Braided Clutch Line, ROH Mantis 18*7.5+45.

    Growing old is compulsory... Growing up is optional...

  20. #20
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    Additionally... posts on US forums seem to indicate that no matter what you do, the leak will return in time...

    Looking at the design of the case, all power going through it is trying to pry the case apart across the joint surface, no wonder they all leak eventually.

    Aditionally... my gearbox whines quite a bit in second... only really at light-mid throttle though...

    Chris.

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