Transfer Case problems of the 2010 Mazda CX9

2010 Mazda cx-9 awd touring with under 120,000 miles. The vehicle would make a noise like driving over rumble strips in the road, vibrating the undercarriage. It started happening when lightly pressing the accelerator, trying to maintain speed, normally at 1500rpm then it gradually got worse and happened all the time and the noise got louder. Sometimes there would be a burning smell. I spent $1000+ on "fixes" before discovering it was the transfer case, another $2,000+. Since Mazda already knows about the issue and has provided 2 extended warranties for this issue, the transfer case for the defective years/models should be on them. After researching this problem I have seen many people having to replace the transfer case multiple times.

Transfer case for my Mazda cx-9 has gone bad for the third time since I have owned this vehicle. Most recently the transfer case was burning causing a powerful smell which went through my entire house. The smell was so bad that I actually called the fire department to verify I did not have natural gas leak. This is a known issue with the cx-9 and defective transfer cases. My local dealership has assisted me and tried to reduce repair costs as much as possible. However, Mazda refuses to fully cover part which most likely caused my transmission failure as well in August 2018.

The transfer case was replaced at 34,000 miles and now we are having to replace the transfer case again. Additional transmission damage may have occurred. Mazda refuses to stand behind their product and admit to a design flaw. The first transfer case smelled like propane. The second transfer case had gear grinding noise.

I was driving my 2010 Mazda Cx9 when a loud bang happened. I was on a side road and stopped immediately, I could not visibly see any issues. I began to drive slowly and with every rotation the noise continued. Luckily I was next a a garage and they determined it with the power transfer unit (case). They had told me this is a very common issue and that Mazda even knew of this issue but never had a recall placed. After researching and seeing multiple years of this issue for the cx 9 and even an extended warranty something has to give Mazda. Basically the front transfer case (or power transfer unit, ptu) is too close to the exhaust system and gets heated up more than usual. The gear lubricant inside gets deteriorated a lot faster and becomes sludge. In theory gear lubricant in front transfer case、rear differential、and manual transmission can be "life-time" lub under a suitable environment, hence Mazda and Ford don't specify any recommended maintenance interval for gear lubricant replacement and don't even bother to design a drain hole for it! but since the gear lub actually gets heat up so often, it causes problems and makes the front transfer case eventually failed due to sludge issue. I have read 100's of complaints and still no resolution except for the people that claim they called Mazda directly and after months of complaints were handled individually. I have been a lifetime Mazda owner from my first 1986 Mazda 323 and this has been a nightmare. A recall has to be made with this number of complaints and issues. $3000 out of pocket for a known issue with your vehicle is unacceptable.

Transfer case failure cabin filling with acid smoke from bearing failure in transfer case, car was driven to local garage for replacement not covered even though there is numerous failures with this car. Mazda has made numerous changes in this design so why isnt there a recall . This happened when my car was at a stop sign. This is a common problem with this car that could lead to someone to panic with such horrible smelling smoke.

Tl the contact owns a 2010 mada cx-9. While driving unknown speeds, a smoke odor entered the vehicle. The vehicle was taken to an independent mechanic where it was diagnosed that the transfer case bearing was burnt due to sludge. The contact called Mazda of milford at 66-981-2838 and was informed to bring the vehicle in for diagnostic testing. The vehicle was repaired. The manufacturer was notified of the failure. The approximate failure mileage was 137,000.

Car was making grinding sounds when the vehicle was in motion, especially when I turned left/right as well as when I was stopping the vehicle. Most noticeable on city streets. Needed to replace transfer case and transmission.

Tl-the contact owns a 2010 Mazda cx-9. The contact stated that while moving off from a traffic light the vehicle exhibited an abnormal burning odor coming from the front of the vehicle. The vehicle was taken to the dealer where the contact was notified that the transfer case had a leak. The vehicle was not repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 77,200. Ah.

When I got in the car, the check tire pressure light was on. Stopped at a service station and had the tires checked: all was fine. A few miles later, the car suddenly made a loud whining noise and then loud banging noises and the car felt like it was seizing and shuddering. Pulled to the side of the road, couldn't see anything amiss under the hood. Re-started the car and headed home with the loud whining noise upon any acceleration. I called the dealership the next day and had it towed to them as I felt it was unsafe to drive after doing some research and noting the symptoms were similar to what other vehicle owners had reported as a transfer case failure. Upon examination the dealership did say it was a transfer case failure and replaced it that day. I picked up my car today and so far it is driving and handling fine. Several months prior to the vehicle failure I had noted a very, very faint whining noise when my speed was between 30 and 40 mph. I had my mechanic (not the dealer) try to examine the noise when he did my routine 30k mile service. The noise was so faint he was not able to detect it. He wasn't able to find any Mazda service bulletins that indicated a problem to examine further. Besides that faint whining noise there were no other indications such a dangerous vehicle failure was going to occur, and the car checked out fine at that 30k routine service. Not sure why the check tire pressure light came on immediately prior to the failure but the dealer said they "reset" it when they replaced the transfer case. The dealer was very prompt and professional in their response and treated us very well. But I do feel this issue is so serious we should have received notice from Mazda with a request to get the transfer case examined earlier.

The contact owns a 2010 Mazda Cx9. The contact stated that the vehicle exhibited an overpowering burning odor from the vents. In addition, a loud knocking sound came from under the hood. The contact took the vehicle to the dealer and was told that the transfer case needed to be replaced. The dealer test drove the vehicle and the engine seized. The vehicle had not been repaired. The failure mileage and current mileages were 26,900.

I noticed a strange smell in the vehicle. I drove a few blocks to home (luckily). Engine compartment was smoking as I pulled in the driveway. This was diagnosed by a mechanic as a cracked transfer case. Leaking fluid from the case was the source of the smoke; not covered under warrantee by Mazda nor is there a TSB for the problem. A quick search showed that transfer case problems are common for this vehicle. This could have been a serious road hazard.

This car is maintained to manufacturer's requirements. Smoke filled the drivers cabin, coming from oil dripping out of the failed power transfer case, dripping onto the exhaust pipe and rising smoke into the cabin. This was unsafe and the car became unusable over a few days. I had the transfer case repaired at a cost of $1395. 89, including associated cost of $136. 36 for a rental vehicle replacement. I paid for the repair with a private extended warranty, that was not part of Mazda, to pay the repair shop. When I applied for reimbursement under Mazda's "special service program 92 (2010-2014 Cx9 awd power transfer unit warranty extension)", I received a letter from Mazda north american operations denying me reimbursement, because I paid for the repair using my personal warranty policy. Since I purchased this personal warranty policy, (not Mazda), I believe I am entitled to reimbursement for the repair.

I was driving on a street with a 25 mph speed limit when all of a sudden the car hesitated and made some weird noises. I continued to pull over to get out of the way when there was a huge bang and the car came to an sudden stop. I was able to get to the side of the road. Smoke was coming out of the engine area and the car smelled terrible. I jumped out, got my dog out and called 911. The fire department and police came. Found metal parts all over the road. Smoke was mainly due to oil that was all over the engine and bottom of car. Right now the initial diagnosis is that the transfer casing blew along with a variety of other parts. Thank goodness I was not on the freeway. Additionally, I was lucky that the large parts that blew off the car did not put a hole in the bottom of my car or damage someone else's car.

Transfer case was first replaced in July 2012 with an oem part and now again 8 months later. Leaking gear oil, terrible smell coming into compartment of car and also had clunking sounds in front driver side axel.

Tell us what happened: transfer case is bad. Dealer says this is a known problem and that Mazda has this issue with cars directly from the factory. Known issues should be recalled! I bring my vehicle in for regular maintence, I should not have to break down with children in the car for a problem that Mazda knows my car has! the failure is so widespread there is a nation wide shortage.