Transmission Transfer Case

[Marijo]

Hello,

I am new to this site. I have a 1998 Outback Ltd. The transmission transfer case was replaced at 40,000 miles and needs to be replaced again at 79,600 miles. I called Subaru Main Headquarters customer service and they offered to pay 500.00 of the 1600.00 cost to replace the transfer case.

 

The dealer, as well as Subaru, is unable to explain why my car has this problem. It is not a tire problem as I have always had matched tires on the car.

 

I am looking for more information. Should I be selling the car? It seems to me that if it happened twice, each time at 40K it will most likely happen again in 40K. Should I look to Subaru to do more than $500? Does anyone know someone at Subaru headquarters who could offer more info or help? Any information you have will be appreciated.

 

Thanks and Happy Holidays,

Marijo

[nipper]

First off the car does not have a transfer case. It has a clutch pack at the end of the transmission (if an automatic), or a viscous coupling with a differnential if its a manual. These systems can go for 100,000's miles with just regular maintanence.

 

These are very robust systems, and you really need to examine WHY its going bad.

Are all your tires at the same pressure. Are all your tires of equal wear. The quickest way to kill the AWD is to have mismatched tires. If its an automatic did you check the transmission level.

What are the symptons that you have.

 

 

nipper

[Marijo]

Hi Nipper,

 

Thanks for your response. I asked the man in the service department who gave me the quote for the repair to please write down the parts that need replacing so that I could discuss it using the proper words. To quote him "Transmission transfer case is going bad." I do not know what it means when you say my car doesn't have one...?

 

My tires are in excellent shape. I have my car maintained regularly. I have never had mismatched tires, and when the dealer looked at my car, they checked the transmission level and the tires and cannot explain why this problem is occurring. Expecially two times in only 80K miles.

 

These are the symptoms per what the service department wrote down: "Has a hard shift when accelerating and a vibration during tight turns. Transfer case was replaced once before at 40086 in July 2001."

 

I appreciate your response. I feel like I am still in the dark about his and the mechanic at the dealer can offer no explanation. Apparently he is in the dark about it as well.

 

Any other thoughts? Thanks again for responding. I agree with you, I'd sure like to know why it is going bad. I am wondering if it is a problem that Subaru has had with certain models. I find it suspicious that they are willing to pay for one third of the repair.

 

Hope you are having a nice holiday.

 

Marijo

 

 

 

 

First off the car does not have a transfer case. It has a clutch pack at the end of the transmission (if an automatic), or a viscous coupling with a differnential if its a manual. These systems can go for 100,000's miles with just regular maintanence.

 

These are very robust systems, and you really need to examine WHY its going bad.

Are all your tires at the same pressure. Are all your tires of equal wear. The quickest way to kill the AWD is to have mismatched tires. If its an automatic did you check the transmission level.

What are the symptons that you have.

 

 

nipper

[nipper]

im almost tempted to say repalce the entire transmission, in fact demand it. The only thing i can think of is that there is something internally wrong with one of the internal shafts that may be side loading the unit. Ild have them chack all the motor mounts, the carrier bearing (its in the middle of the car and suports the driveshaft). Check your tranny fluid is it burnt? There is something else going on here and i think the clutch assembly is getting the brunt of the stress. Something is either bent, or the tranny has an internal fault.

Do you have a lemon law in your state?

For now you can put the FWD fuse in the car and drive it that way. Have you gone to another dealer or a transmission shop for a second opinion, and tell them whats been done already. Has this car has never been hit before? Really 500.00 on a main drivetrain part that was replaced at 40K something is very wrong. This is not something that you can screw up unless you have mismatched tires on it, and you already said you havent.

 

nipper

[avk]

Don't take it like I know what I am talking about, but from the factory manual, it appears that replacing either transfer clutch plates or solenoid C requires some careful measurements and ordering certain parts based on them. In my impression, it's kind of like replacing engine bearings or piston rings. Probably not an issue if the extension a.k.a. tailshaft housing (that's the name) is replaced as a complete unit but in any case, anyone working on it really has to know what they are doing.

[thenak]

Duty solenoid is pretty standard.  clutch pack comes out with the drum as an assembly yielding access to the pipe (which must be removed to gain access to the solenoid).

The pressure plate and drive plates and driven plates (not a typo) are secured and removable via a snap ring.  The piston and other "deeper" components appear to require special tools to remove, but not necessary to do so if just doing a simple overhaul of the clutch pack.

[el_freddo]

Wow 13 year thread dig!

 

Epic!!

[CNY_Dave]