Transfer case recall [ merged ]

[boostman]

All transfer case recall threads are merged here.

Does anybody have a number i can call to see if my cars had the recall done?thanks.

 

[Raynehr]

I own a 1991 Eclipse GSX, I purchased it from a friend who told me that the transfer case had problems. The transfer case has had the recall issued on it in 1998, where i do have the original 1998 service ticket where all they did was raise the car and check it for leakage, and pull it off the rack. The transfer case seized in 2000, and the car was parked. I purchased it in 2005. I began looking into the recall. Noticed it was a lifetime recall, however since the recall had already been issued on the car, even though I still have the defective grease leaking plug on the car, the mitsubishi company will not even look at it for less than $85 an hour. Now i have a wonderful yard ornament until i find another faulty 23 spline transfer case to go into my car, or shell out $600+ to get it rebuilt. So much for a lifetime recall on defective parts.

 

[Pure92TSi]

If all they did was raise it and look at it and not actually perform the recall you do have a case against them. If you know anyone lawyers or have a friend that knows one see if they will draw you up some papers and present them to the dealership. Most likely they will just do the service instead of messing with legal matters. But first you should just fight with them about it and try to go over their heads directly to Mitsubishi Corporate offices.

 

[Raynehr]

Appreciate the advice.. and did call the mitsu offices. they gave me the same shpeil. since it has been performed that they are not liable. Even called the NHTSA.. since the recall has been performed, even though there are still faulty parts on the car.. nothing

 

[firehawk]

That sounds very odd, havn't I read that it is a lifetime recall. Not a you can bring it in once, we will see what we can do recall, but they have to continue to fix it for the lifetime of the vehicle...even if it craps out every week


Ahh...here it is...

http://www.dsmtuners.com/forums/showthread.php?t=19280

 

[weith1111]

Don't listen to that BS crap from Mitsu:

http://dsmtuners.com/forums/showthread.php?t=19280

They will take it and they fix it.

^^^beat me to it!

 

[Raynehr]

I have a 1991 gsx eclipse, the recall has been performed. However in 1998 the car was put on a lift, checked for leaks, and sent out the door (the service ticket was in the glovebox). The transfer case locked up in 2000, and the car has been sitting ever since. Now that I recently purchased the car, i am looking into the recall to have it fixed properly and mitsubishi has flat refused any service on the transfer case because the recall has already been performed, and the defective parts are still on the car. They dont seem to care however because they did there 10 minuites of work in 1998, and dont feel liable for any repairs since there was grease still in the transfer case in 1998. Now my options, i can buy a used one and stick in it and wait for it to grenade, or i can shell out $500 to $600 for a transfer case rebuild.

 

[Doug99RS]

I really don't understand why these threads keep being brought about as if the answers aren't out there. It's simple let me explain one last time.

--Mitsubishi vehicles must go to Mitsubishi.

--Eagle must go to Eagle.

--The transfer case going IN TO the car for the recall has to match the one originally installed in the car. If you swapped your stuff around then you're SOL because a recall is vehicle specific. If you have a different transfer case part number billed out that doesn't match the vehicle the manufacturer says "Hey, they're trying to put on part Y when part X was required. Warranty (recall) claim rejected." And don't think the dealership will just order the part that is in your car and wait until the dust settles to deal with the part discrepancy.

-- Eagle was a division of Chrysler Corporation, not DSM, Not DSC, nothing else. It was a Mitsu with an Eagle Badge thus making it chrysler as far as warranty and recalls go.

--Chrysler honors a recall for the life of the car. A recall is a recall for life. If the part being replaced fails again in the ------EXACT------ manor in which the recall describes then you get the part replaced again for no charge AT A CHRYSLER/JEEP/DODGE dealership. When many Jeep Dealerships merged with Chrysler they did so under the stipulation that the Eagle brand follows the Jeep brand.

--If you own a Mitsubishi and the recall was performed 95% of the time you are SOL and won't EVER get it covered no matter how big of a temper tantrum you throw.

--Chrysler's Recall notification number is 780. There are NO CURRENT TSBs regarding this condition. On other recalls chysler has had we will frequently see a TSB prior to a recall. When the recall is launched it supercedes the TSB and sometimes varies the repair procedure.

-- Through Chrysler the recall covers:
Models:
• 1990 Through 1998 Model Year Eagle Talon TSi All Wheel Drive (BD/FJ24) Vehicles Built Through February 2, 1998 (MDH 0202XX)

• 1992 Through 1994 Model Year Plymouth Laser RS All Wheel Drive (BD) Vehicles

--Finally here is the dealerships recall notification itself. These are the instructions the tech HAS to follow and in the order listed. Failure to perform the recall EXACTLY by the guidelines of the recall notification puts him in jeopardy with federal laws governing recall/transportation safety/repair procedures. If you have any questions READ THE OTHER THREADS REGUARDING THE RECALL!!!! If you still don't find what you're looking for call the numbers listed at the bottom of this information below


The transfer case on about 42,000 of the above listed vehicles, may develop an oil leak and/or have a low oil level. This could result in transfer case bearing failure and wheel lockup. To correct this condition, the transfer case oil level must be checked and the transfer case and driveshaft yoke must be inspected for leaks and repaired if necessary. In addition, the transfer case must be replaced if it exhibits abnormal noise or has no oil (ignore normal gear noise such as high pitch whine).

IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory, and should perform this recall on vehicles in for service as determined by using the DIAL VIP System.

Dealer Notification & Vehicle List
All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles.

DIAL System Functions 53 and VIP

All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed.

Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claimsubmission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD780".

Parts
Driveshaft Yoke Packages:
IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand.

Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Driveshaft Yoke Packages, Recall PN CCFE7801, to service about 10% of those vehicles.

Each parts package contains the following components:

Quantity Description
1 Driveshaft Yoke and Universal Joint
2 Universal Joint Journal Bearings
8 Snap Rings



Oil Level Gauge:

Each Chrysler-Plymouth and Jeep & Eagle dealer will be provided with ONE (1) Transfer Case Oil Level Gauge. The gauge is enclosed with the dealer recall notification letter that was sent by first class mail to involved dealers. Additional Oil Level Gauges, PN MR470416, may be ordered as necessary at dealer cost.

Transfer Case Assembly:
IMPORTANT: Each vehicle should be inspected before a replacement transfer case is ordered. VERY FEW VEHICLES ARE EXPECTED TO REQUIRE TRANSFER CASE REPLACEMENT.

If the transfer case requires replacement as determined by the inspection procedure, dealers should order the appropriate transfer case listed below:

Model Year
Transmission
Part Number

1990 Manual MD743709
1991 through 1996 Automatic MD758203
Manual MD758205
1997 through 1998 Automatic MD748595
Manual MD748594





Transfer Case Oil Seals/Gaskets:
If a transfer case oil seal or gasket must be replaced as determined by the inspection procedure (Section A), dealers should order the appropriate part number listed below:

Oil Seal/Gasket
Transaxle
Part Number

Drain Plug Gasket All MD000312
Fill Plug Gasket All MF660036
Input Shaft Oil Seal Manual MD723202
Automatic MD731793
Output Shaft Oil Seal All MD701430
Case Upper Cover Gasket 1990 MD736349
1991-1998 MD752981
Gear Case O-Ring All MF520414
Front Case Driveshaft Cover O-Ring All MD727944




Owner Notification and Service Scheduling

All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is attached.

Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed.

Service Procedure
Inspect Transfer Case:
Road test the vehicle to check for any abnormal noise or grinding sounds from the transfer case. If any abnormal noises or grinding sounds are heard, the transfer case must be replaced. (Ignore normal gear noise such as high pitch whine.)
Raise the vehicle on an appropriate hoist.
Remove the transfer case oil filler plug. Check the amount of oil in the transfer case by inserting the provided transfer case oil level gauge (PN MR470416) into the oil filler hole (Figure 1).
If the transfer case oil level registers anywhere on the gauge, the oil level is sufficient, continue with Step 5.
If the transfer case oil level does NOT register on the gauge, continue with Step 4.
NOTE: If fill plug shows signs of leakage, replace the fill plug gasket.

For all vehicles with low oil levels: Remove the transfer case oil drain plug (Figure 2).
If oil runs out or drips continuously, transfer case replacement is NOT required.
If NO OIL or only A FEW DROPS OF OIL come out, the transfer case MUST be replaced. Continue with Section B.
NOTE: If drain plug shows signs of leakage, replace the drain plug gasket.

Inspect the driveshaft yoke plug and front exhaust pipe (Figure 3) for signs of oil leakage. If signs of leakage from the yoke are evident, the driveshaft yoke must be replaced.
IMPORTANT: The driveshaft yoke MUST be replaced on ALL 1998 model year vehicles.

Inspect the transfer case for indications of any oil leakage. Any transfer case oil leak must be repaired.

If the driveshaft yoke, input and/or output shaft oil seal, and/or transfer case require replacement, continue with Section B.
If the transfer case oil leak is from a component that requires transfer case disassembly (case upper cover gasket, gear case O-ring, front case driveshaft cover O-ring or reseal case-to-extension housing), refer to the service manual for the repair procedure.
If the transfer case does NOT require replacement and there are no signs of oil leakage:
Reinstall the transfer case drain plug (if removed).
Fill the transfer case with hypoid gear oil (SAE 75W-85W GL-4 or higher) (Figure 2).
Install the transfer case oil filler plug.
Lower the vehicle and return it to the customer. No further action is required.
Driveshaft Yoke, Input Shaft Oil Seal, Output Shaft Oil Seal and/or Transfer Case Replacement:
NOTE: Refer to the service manual for other oil leak repair procedures that require transfer case disassembly.

Inscribe mating marks on the differential companion flange and the flange yoke (1995-1998 vehicles) or on the driveshaft C/V joint (1990-1994 vehicles) (Figure 4).
Disconnect the driveshaft from the differential (1995-1998 vehicles) or disconnect the driveshaft C/V joint (1990-1994 vehicles) (Figure 4).
For 1995-1998 vehicles, remove the heat shield from the front driveshaft support.
Remove the driveshaft support(s) and carefully remove the driveshaft.
FOR VEHICLES THAT REQUIRE DRIVESHAFT YOKE REPLACEMENT:
NOTE: Complete this step on ALL 1998 model year vehicles and any prior model year vehicle that exhibited signs of leakage from the driveshaft yoke.

Remove the snap rings that secure the universal joint to the driveshaft (Figure 5).
Using Special Tool MB990840 (or equivalent), press the bearing journal out of one side of the driveshaft (Figure 6).
Turn the driveshaft over and press out the opposite bearing journal.
Remove and discard the driveshaft yoke and universal joint.
Grease the driveshaft journals and the two supplied journal bearings with Mopar Multi-Purpose Grease or equivalent.
Install the provided driveshaft yoke and universal joint assembly on the driveshaft.
Press one of the supplied journal bearings into the driveshaft using Special ToolMB990840 or equivalent (Figure 6).
Turn the driveshaft over and press in the opposite bearing journal until the snap ring groove is fully visible.
Install a snap ring into one of the driveshaft snap ring grooves.
Using a brass bar, press the universal joint from the other side until it contacts the snap ring.
Install a snap ring in the groove on the other side of the driveshaft.
IMPORTANT: BOTH snap rings MUST be the same size (thickness). Four (4) different thickness snap ring pairs have been provided (1.28 mm, 1.31 mm, 1.34 mm, 1.37 mm).

With a feeler gauge, measure the clearance between the snap ring and the journal bearing (Figure 7). If the clearance is not between 0.01 - 0.03 mm, remove the snap rings and repeat Steps 5I - 5K with the appropriate snap ring pair as necessary.
FOR VEHICLES THAT REQUIRE TRANSFER CASE OUTPUT SHAFT OIL SEAL REPLACEMENT:
NOTE: Only complete this step on vehicles that exhibited signs of leakage from the transfer case output shaft seal.

Remove the output shaft oil seal from the transfer case.
Using special tools MD998822 and MD998812, press the new output shaft oil seal (PN MD701430) into the transfer case (Figure 8).
FOR VEHICLES THAT REQUIRE TRANSFER CASE REPLACEMENT OR TRANSFER CASE INPUT SHAFT OIL SEAL REPLACEMENT:
NOTE: Only complete this step on vehicles that require transfer case replacement or on vehicles that exhibit signs of leakage from the input shaft seal.

Disconnect the front exhaust pipe from the turbocharger.
For 1990-1994 vehicles: Disconnect the exhaust hanger just in front of the catalytic converter.
Remove the six (6) bolts that attach the transfer case to the transaxle (Figure 9).
Separate the transfer case from the transaxle (use a plastic hammer if necessary) andremove the transfer case from the transaxle by tilting the case downward.
FOR VEHICLES THAT REQUIRE TRANSFER CASE INPUT SHAFT OIL SEAL REPLACEMENT: Remove the transfer case input shaft oil seal and install a new input shaft oil seal (Manual -- PN MD723202 or Automatic -- PN MD731793) using special tools MB998833 and MB990938 (Figure 10). Lightly coat the new seal with the recommended gear oil.
Install the new transfer case assembly (or original transfer case with new input shaft oil seal). Tighten the six (6) attaching bolts to 52 ft-lbs (70 N•m) (automatic transaxle) or 42 ft-lbs (57.5 N•m) (manual transaxle).
For 1990-1994 vehicles: Connect the front exhaust hanger.
Connect the front exhaust pipe to the turbocharger. Tighten the attaching bolts to 36 ft-lbs (50 N•m). Tighten the bracket bolt to 26 ft-lbs (35 N•m).
Lightly coat the driveshaft yoke with the recommended gear oil, insert the driveshaft yoke into the transfer case and then install the center driveshaft supports.
Install the driveshaft by aligning the mating marks (Figure 4) and then connecting the driveshaft to the differential (1995-1998 vehicles) or connecting the driveshaft C/V joint (1990-1994 vehicles). Tighten the driveshaft support and driveshaft-to-differential nuts or C/V joint nuts to 22 ft-lbs (29 N•m).
For 1995-1998 vehicles: Install the heat shield on the front driveshaft support.
Reinstall the transfer case drain plug (if removed).
Fill the transfer case with hypoid gear oil (SAE 75W-85W GL-4 or higher).
Install the transfer case oil filler plug.
Lower the vehicle.
Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments.

Use one of the following labor operation numbers and time allowances:

Labor Operation Time

Number Allowance

Description Labor Op. No. Time
Inspect transfer case 21780181 0.3 Hrs.
Inspect transfer case, replace driveshaft yoke 21780182 1.3 Hrs.
Inspect transfer case, replace transfer case and/or output shaft seal 21780183 1.5 Hrs.
Inspect transfer case, replace driveshaft yoke and transfer case or input shaft seal or input shaft oil seal 21780184 2.0 Hrs.
Inspect transfer case and disassemble transfer case to replace upper cover gasket, gear case O-ring, front case driveshaft cover O-ring and/or reseal case-to-extension housing 21780185 2.1 Hrs.
Inspect transfer case, replace driveshaft yoke and disassemble transfer case to replace upper cover gasket, gear case O-ring, front case driveshaft cover O-ring and/or reseal case-to-extension housing 21780186 2.5 Hrs.


Add the cost of the recall parts plus applicable dealer allowance to your claim.

Parts Return

Initially, a small number of transfer cases are required to be returned to the Warranty Material Return Center. When an adequate number of returned parts have been accumulated, Parts Return Documents will no longer be generated and parts are to be discarded.

Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing and material return instructions.

Vehicle Not Available
If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to:

Chrysler Corporation
CIMS 482-00-85
800 Chrysler Drive East
Auburn Hills, Michigan 48326-2757


Following the above procedures will expedite the processing of your claim.

If you have any questions or need assistance in completing this action, please contact your Zone Service Office.

Customer Services Field Operations
Chrysler Corporation

IMPORTANT
DEALER SERVICE INSTRUCTIONS
Safety Recall #780 -- Transfer Case Oil Leaks
This service requirement applies only to:
1990 Through 1998 Model Year Eagle Talon TSi All Wheel Drive (BD/FJ24) Vehicles Built Through February 2, 1998 (MDH 0202XX)
1992 Through 1994 Model Year Plymouth Laser RS All Wheel Drive (BD) Vehicles
The transfer case on the above listed vehicles, may develop an oil leak and/or have a low oil level. This could result in transfer case bearing failure and wheel lockup. To correct this condition, the transfer case oil level must be checked and the transfer case and driveshaft yoke must be inspected for leaks and repaired if necessary. In addition, the transfer case must be replaced if it exhibits abnormal noise or has no oil (ignore normal gear noise such as high pitch whine).
Alternate Transportation:
If inspection determines that transfer case replacement is required and the vehicle must be held overnight, dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle.
Parts Packages:
Each involved dealer, to whom vehicles in the recall were invoiced, will receive enough Driveshaft Yoke Packages to service about 10% of those vehicles.
Due to the very small number of vehicles expected to require transfer case replacement, dealers are requested to order transfer cases only after inspection has determined that replacement is required.

--------------------------------------------------------------------------------




--------------------------------------------------------------------------------

SAFETY RECALL TO INSPECT YOUR VEHICLE’S TRANSFER CASE AND DRIVESHAFT YOKE FOR LEAKS AND REPAIR THEM IF NECESSARY
Dear Talon or Laser Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1990 through 1998 Eagle Talon TSi and 1992 through 1994 Plymouth Laser RS vehicles equipped with all wheel drive.

The problem is... The transfer case on your Talon or Laser (identified on the enclosed form), may develop an oil leak and/or have a low oil level. This may cause the wheels to lock up and result in an accident without prior warning.
What Chrysler and your dealer will do... Chrysler will repair your Talon or Laser free of charge (parts and labor). To do this, your dealer will inspect the transfer case, adjust the oil level and repair or replace the transfer case as necessary. In addition, driveshaft yoke will be inspected for leaks and replaced if necessary. The inspection will take about ½ hour to complete. Repairs, if necessary, may require an additional two hours. However, additional time may be necessary depending on how dealer appointments are scheduled and processed.
What you must do to ensure your safety... • Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment.

• Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer.

If you need help... If you have trouble getting your vehicle inspected and repaired (if necessary), please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle serviced. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 1-202-366-0123.)


We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter.

Customer Services Field Operations
Chrysler Corporation
780

 

[Ski Bum]

About 2 weeks after my dealership performed the transfer case recall consisting of a new U-joint and yoke seal and fluid refill I noticed a leak coming from the rear differential. A few weeks before I had the recall done I replaced the rear diff fluid with Redline Shockproof gear oil per reccomendations here. At that time the diff was dry as a bone on the outside indicating no leaks and full of fairly clean factory oil, or so it appeared. I never heard any humming or whinning from the diff so I figured it was in good shape.

It turns out the leak is coming from the point where the driveshaft enters the differential. I took the car back to the dealership for them to inspect and question whether the transfer case recall may have caused this issue. They told me it was the rear pinion seal and that during the recall service they did not touch that area and were not at fault.

Are they blowing smoke up my ass or could they have caused a problem? I cant imagine its just a coincidence.

Any help is appreciated.

 

[robs90tsi]

I think that it could be the fluid swap, that redline stuff is synthetic right??? If it is, then that could be it, it may have removed the buildup around the seal and just started to leak, or its just a coincedence, but if the dealership had anything to do with it, then they will not tell you, I worked at a dealership and trust me, if they did that, they will not tell you, but I dont think that the dealership could ruin your rear pinion seal just from removing your driveshaft.

 

[Staytuned]

A leak at the rear diff would not be caused by the T-case recall. This is either pure coincidence or caused by the extra thick shock proof gear oil. I use Redline 75W90 gear oil in my rear diff not shock proof gear oil as per Redline's instruction.

 

[Ski Bum]

Can that seal be replaced very easily? Could I luck out and juut be able to replace the seal and fluid?

 

[robs90tsi]

Its not too bad, if you have a fair amount of mechanical know-how, and the tools, then yes, the seal and fluid could be replaced sucessfully.

 

[Ski Bum]

This may not be related but I figure its worth investigating. When I engage the clutch while in gear I can hear and feel and fairly abrupt clunk coming from somewhere in the drivetrain. I usually notice it at slower speeds like in a parking lot while in 1st gear, then engaging the clutch to stop. As soon as the clutch is engaged and the gear is released the clunk occurs. This also occurs during normal acceleration shifting from 1st to 2nd. There is a clunk when I engage the clutch to go from 1st to 2nd then another clunk (less noticeable) when relesing the clutch once 2nd gear is attained. I have tried to find a way to avoid this as iny clunk cant be good and the only method I have found and it is still not 100% of the time is to slip the clutch quite abit going in or out of gears. I only do this at low speeds, less than 15mph.

This is straight from the factory service manual:

DIFFERENTIAL (LIMITED
SLIP DIFFERENTIAL)
Abnormal noise during driv- Excessive final drive gear backlash Adjusting or gear changing Insufficient drive pinion preload
Excessive differential gear backlash - Adjust or replace
Worn spline of a side gear Replace
Loose companion flange self-locking nut Retighten or replace

Is backlash what I'm feeling?

BTW

A leak at the rear diff would not be caused by the T-case recall. This is either pure coincidence or caused by the extra thick shock proof gear oil. I use Redline 75W90 gear oil in my rear diff not shock proof gear oil as per Redline's instruction.

Which version of that do you use? The 75w90NS with the friction modifiers or the regular? The type with the friction modifiers is reccomended for the WRX rear diff.

 

[robs90tsi]

This may not be related but I figure its worth investigating. When I engage the clutch while in gear I can hear and feel and fairly abrupt clunk coming from somewhere in the drivetrain. I usually notice it at slower speeds like in a parking lot while in 1st gear, then engaging the clutch to stop. As soon as the clutch is engaged and the gear is released the clunk occurs. This also occurs during normal acceleration shifting from 1st to 2nd. There is a clunk when I engage the clutch to go from 1st to 2nd then another clunk (less noticeable) when relesing the clutch once 2nd gear is attained. I have tried to find a way to avoid this as iny clunk cant be good and the only method I have found and it is still not 100% of the time is to slip the clutch quite abit going in or out of gears. I only do this at low speeds, less than 15mph.

This is straight from the factory service manual:

DIFFERENTIAL (LIMITED
SLIP DIFFERENTIAL)
Abnormal noise during driv- Excessive final drive gear backlash Adjusting or gear changing Insufficient drive pinion preload
Excessive differential gear backlash - Adjust or replace
Worn spline of a side gear Replace
Loose companion flange self-locking nut Retighten or replace

Is backlash what I'm feeling?

BTW


Which version of that do you use? The 75w90NS with the friction modifiers or the regular? The type with the friction modifiers is reccomended for the WRX rear diff.

As far as that backlash thing goes, I dont think so, it probably has to do with your clutch disengaging, im not super skilled with diagnosing noises, but Im pretty sure what your hearing has to do with the clutch, not sure exactly what part of the clutch or why, but there is an explination to that kind of noise and your clutch, I just dont know what it is , I got a gut feeling, oh, and use a GL-5 rated fluid, like the Mobil 1 synthetic rear diff fluid, that stuff works fine, its what I use.

 

[Staytuned]

Which version of that do you use? The 75w90NS with the friction modifiers or the regular? The type with the friction modifiers is reccomended for the WRX rear diff.

I use the regular 75W90 to avoid any chance of LSD chatter associated with the NS additive.

 

[Staytuned]

I think the clunking you hear might be carrier bearing related, not rear diff. Rear diff back lash noise would be more of a howling sound when driving not a clunking noise.

 

[demografik]

Here's a new one. My car is at a dealership right now, they took the case off and said it's definitely locked up but their District Manager won't let them do the recall. I called the Mitsu 800 number and spoke to a 'Case Manager' and was told that due to the mileage (160k) they couldn't honor the recall. I told her I have a copy of the recall sitting in front of me and that I had spoken to the NHTSA and that both of them said mileage had nothing to do with it but no dice. I called the NHTSA and they said all I can do with them is file a complaint which I fear won't do shit. What should I do now?

 

[Boosted98gsx]

Go find the document (it is online at the NHTSA website) that states the penalty for refusing to perform an NHTSA recall. I believe it's somewhere around a $15 million fine.

My local mitsu dealer in houston (that originally performed the recall) refused to do it again as there were no signs of a leak when i brought it in the first time. However, the 2nd time there was an obvious leak. Just like you, the District Manager told them not to do it. So I went and found this penalty document and told them that if they did not honor the warranty, I would be filing suit for the full fine charge. Low and behold, it got done.

I had everything still on the car, too. Full 3" catless exhaust, no emissions, loping like hell cams, etc. Warranty was obviously voided from aftermarket parts. The parts mnger even asked me how I passed emissions with it. But it still got done.

Found the document for you.

http://www.nhtsa.dot.gov/nhtsa/Cfc_title49/publ414.106.pdf

Page 5 Section 5, starting with "(1) In General- A person that violates

Emphasis on PERSON because if the District Manager refuses, then it's HIS ass that gets sued for not more than $5000. I had to tell the parts manager to make sure he was aware of this.

 

[demografik]

What about the NHTSA telling me their recalls are only good for 10 years after the original purchase of the vehicle?


#

Are there any limitations on my right to have my vehicle remedied at no charge?

Yes. In order to be eligible for free remedy, the vehicle cannot be more than 10 years old on the date the defect or non-compliance is determined. Under the law, the age of the vehicle is calculated from the date of sale to the first purchaser.

 

[sweet97]

Too bad the case locked up. Mine sytarted to leak and they ran the VIN and said it had been done once and that was it. I said that safety recalls had to be performed for the life of the vehicle. No dice. I spent the $80. for the parts and had the yoke changed, wasn't worth the hassle for me but my case was still good. Best of luck, Mark

 

[Doug99RS]

What about the NHTSA telling me their recalls are only good for 10 years after the original purchase of the vehicle?


#

Are there any limitations on my right to have my vehicle remedied at no charge?

I've been doing recalls on vehicles that fall outside of that range for quite a while. The only way I could imagine a recall being affected by a build date would be like this:

Vehicle built in 2006. Current year is now 2017. Vehicle will never have a recall because it made it this long without an issue.

As far as not honoring a recall that came out before the car was ten years old... I've never heard of it not being honored (for the first time) because of the in service date. I just ran a VIN number for a guy and he still had the lower lateral arm recall open on his talon AWD. It still showed it as being unperformed and he'll be getting his replaced for free shortly.

I've also never heard of a chrysler/jeep/eagle dealership not honoring a recall for the life of the car. I know there's certain times where the nature of the repair prevents the recall from ever being an issue again. Like the complete removal of the secondary air issue on the 2gnt's. Obviously if you remove the component then it can never fail in the same manor in the future. So obviously one repair only. But in the case of leaking transfer cases, bad lower lateral arms and such those recalls should be covered for life.
D

 

[demografik]

What do you suggest I do? Mitsu told me they don't have to do it, NHTSA told me it's outside coverage. I'm planning on calling the dealership tomorrow and trying to bluff them unless you have a better idea.

 

[Doug99RS]

What do you suggest I do? Mitsu told me they don't have to do it, NHTSA told me it's outside coverage. I'm planning on calling the dealership tomorrow and trying to bluff them unless you have a better idea.

There's been very few instances where a mitsubishi branded product has ever gotten support after the original recall was "performed". I doubt you'll have any better luck. Maybe find a buddy with a talon and swap yours in to his car and have it taken back in for the recall again. That's about the best I can offer really given the lack of success other mitsu owners have had.
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[demografik]

The recall hasn't been done before on this car. They're just refusing to do it because they claim it's too old to be covered under the recall. Either due to mileage or the 10 year period the NHTSA claims.

 

[steel_3d]

My t-case was almost empty of oil when I first checked it after I bought the car. A lot of shavings and 1mm chunks came out. It was definitely noisy. This weekend I took it off since I pulled my engine and there's a big tear in the output shaft seal. Been spewing oil ever since I refilled it, obviously.

I'm considering rebuilding it myself since it's out already. Can anyone tell me the part numbers I need?

I see some part numbers for seals and gaskets in the recall instructions posted above, but no part number for the yoke. Anything else I should know about or replace? The recall doc talks about the u-joint as well. Is that part of the yoke assembly or a separate part number?

I'd like to replace the bearings too (they're obviously pretty ground up since there was so much shit in the oil), anybody happen to have the part numbers for all the bearings in the t-case?

Has anyone here ever rebuilt a t-case? I've rebuilt my tranny before, so I have some idea of what would be involved. Do I need to worry about shimming bearings, or it's simpler than that?