Transfer case failure

[geopaj]

Before this incident, I've never broken anything in a drive train - I don't drive that hard.

I can attest to this - before Scott's incident, I had just climbed the same hill in my NT and was watching Scott when he drove the same hill and disaster struck (Me and a few others also helped get it back to camp).

Definitely wasn't getting driven hard or being abused.

[letsgoplaces]

Sorry John.

Their initial inspection claimed it was the failure of the CV due to abuse that triggered the failure in the transfer case, and they gave me a quote to repair it all. At that stage, they hadn't disassembled the transfer case.

I explained that I didn't accept that explanation, along with some reasons for why, and that I wanted to ask Mitsubishi to contribute to the repair. That's when they agreed to remove & disassemble the transfer, and they haven't called me since.

Last week, a representative of Mitsubishi's SA office was due to visit the dealer (for other reasons - not to see my transfer case) and the Service Manager intended to discuss the issue with him. He also stated that he would send my request for assistance "up the line", which is entirely reasonable - this isn't a decision for the dealer to make.

I didn't expect anything to happen quickly, but it would be nice to receive an occasional update. Having said that, I had to wait in the Service Reception while another customer had a long-winded whinge about EGRs and inlet manifold blockages, so I understand that the Service Department does have other things to deal with...

Thanks for that explanation Scott.
Hopefully the SA rep had a look at it and at the same time got an unbiased description of how the damage occurred, and you get a timely resolution.

Cheers
John

[GHendo]

I have heard of low range gears failing in an NP transfer case, which Mitsubishi replaced under warranty with no questions asked - presumably, they chalked that up to a manufacturing defect.

I believe this is the same failure.

Oh, GREAT !! Now you've got me worried

Geoff

[nj swb]

Update: Today I rang the dealer to enquire. My "goodwill repair" request was sent to Mitsubishi at the beginning of last week, and no answer as of yet. The Service Manager kept me on line while he did a lot of key punching (played a game of Tetris, for all I know ) and said there was no response in the system.

Apparently, because of the value of the repair, the request has gone to the top of the Australian tree. So I continue to wait. And hope.

[ticky]

Good luck Scott, hope they come to the party

[Bogger]

http://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=4&cad=rja&uact=8&ved=0CEcQtwIwA2oVChMIh9ialpayxwIVgXumCh0gIAH6&url=http%3A%2F%2Fwww.youtube.com%2Fwatch%3Fv%3D7Br2Akao9_0&ei=XOfSVYe6DIH3mQWgwITQDw&usg=AFQjCNETc-74VvcZdTyuMztBdn833ImyQQ&bvm=bv.99804247,d.dGY

[DaveE66]

I would contact Mitsu customer relations not wait for dealer action.

I agree, when I claimed my driveshaft the dealer said mitsi said no to goodwill claim. I contacted mitsi direct and what do you know they agreed to pay half.

[Kumabear]

Good luck mate hopefully MMAL come to the party and help out, I always hope there is someone in customer relations just watching threads like this unfold.

That may not even be a thing who knows but if it was they would surely realise that the huge amount of goodwill earned by helping a member of a very public forum out is worth more money in the long run than any of the huge amount of cash they spend on advertising every year.

[conquistador]

Update: Today I rang the dealer to enquire. My "goodwill repair" request was sent to Mitsubishi at the beginning of last week, and no answer as of yet. The Service Manager kept me on line while he did a lot of key punching (played a game of Tetris, for all I know ) and said there was no response in the system.

Apparently, because of the value of the repair, the request has gone to the top of the Australian tree. So I continue to wait. And hope.

its probably with the local warranty engineer, who is on holidays

[nj swb]

Well, the phone call came through.

Not unexpectedly, they have opted to not participate in a goodwill repair, claiming that twin diff locks placed too much load on the drive train, leading to the transfer case failing under excessive load.

If you're in low range first gear, Mitsubishi are relying on wheels spinning to protect the transfer case.

I've spoken to two automotive engineers, and they both agree - the transfer won't be sized by Mitsubishi to cope with the full torque in low range first gear. Even if a forensic analysis proved there was a pre-existing defect in the transfer, the chance of obtaining a judgement in a court and having it stick is pretty slim - the cost of the forensic report, if it found something, would probably be more than a replacement transfer.

So, officially, the transfer failed under load.

[schnitzel]

Actually not surprised at there answer, know it hurts the back pocket but don't think any manufacturer would wear it with the mods you have. Don't get me wrong don't think it's 100% right but can understand their logic.

[Gus]

Not a good outcome for you unfortunately, yes can understand but would've thought they'd help out pricing wise.. Let's be honest we all add mods & yes they can effect the drive train under load, more so than if left stock. However, I'd also have to point out that I haven't heard of one failing like yours!

[Ian Sharpe]

Not unexpectedly, they have opted to not participate in a goodwill repair, claiming that twin diff locks placed too much load on the drive train, leading to the transfer case failing under excessive load.

[1]:

Just a cop out, IMO I have been running dual lockers for years in my Paj & havent done a transfer case. In fact Mitsu cases are overbuilt compared to others.

[letsgoplaces]

Not unexpectedly, they have opted to not participate in a goodwill repair

bugga

Are you going to give them the repair?

[nj swb]

Just a cop out, IMO I have been running dual lockers for years in my Paj & havent done a transfer case. In fact Mitsu cases are overbuilt compared to others.

That's what I've always thought, and I was surprised when two automotive engineers that I know & trust supported Mitsubishi's argument - they calculate an expected "resistance" from the tyres on a particular surface, and presume that the torque required to make one of the tyres break traction is the most that the drivetrain will ever see. Aggressive off-road tyres at 15psi with all diffs locked doesn't enter their equations.

I did some maths:

• Peak torque of 440Nm
• Torque converter stall ratio 1.85:1
• First gear 3.52:1
• Low Range 1.9:1

That works out at 5444Nm on the main shaft in the transfer case. According to Mitsubishi, that's enough to strip the low range gears.

Ian, can you do the same calcs with your setup?

bugga

Are you going to give them the repair?

Hi John,

If there's a silver lining to this, I now have freedom to chase low-range reduction gears. So I can produce even more torque in low range in the next transfer case.

Mitsubishi had previously quoted to supply & install a front driveshaft from a (relatively) low km wreck - I'm happy with the price they quoted, so I've asked them to see if the parts are still available, and replace both front shafts. In my opinion, it was the failure of the transfer gears that caused the CV to shatter, so the other front CVs are in question. I'm trying not to think about the rear CVs.

As I'm chasing options to supply an "upgrade", I'll also ask about install options. Fundamentally, I have no issues with having them fit a new transfer case, but first I need to buy one. Depending on what I find where, I might have it fitted somewhere else.

I can't really argue with the Service Manager - it's not his decision and he's stuck in the middle, towing the company line.