Thank you, Bill. The ATF came out after the PTU was pulled. No ATF in the the PTU, just in the transmission/ axle tube area. Does this mean the tranny seal is bad? If yes, do you know the seal is called? It is much easier to order parts if you know what you are asking for... Do I need to replace the other seals on the PTU, or if they look good, reuse them?

 

Without having seen the inside I cannot say. My inference is that ATF should not be there.

Look at whether the seals are easily replaced, many are. If easy, then I'd do so. Consider whether you want to go in again later.

Many are press in rubber type.

 

Thanks again. The way the spline gear from the PTU entered the CVT, I have to assume that I was to drain the trans fluid before starting the job, and am putting that in the lessons learned. As to the seals, they looked like there was a bearing in them, so I took my chances. So far so good. I am back on the road!

 

xspirit:
What was your final resolution? I now have a repetitive thumping that appears to by in sync with wheel rotation (eg 1X). I comes on after the same 15-20 minutes driving. It goes away with hard acceleration, steering input, or light load. Can't ID it yet. Yours sounds similar.

What finally fixed it for you?

 

Nothing to report for mine. It keeps making the noise. If it's getting worse, it must be very slow. It's certainly not going away. If it doesn't develop into anything, I'll have to regard it as some normal noise. There is no thumping or correspondence with wheel rotation on mine.

Yours could be anything from a tire issue all the way to the PTU. Someone better informed might be able to pinpoint it from the symptoms you described.

 

By the way...
With Silverstate Ford the website price is different than what you'll get if you call them up. Had occasion to call thinking I could speak with someone and ensure the right part. As I went to order, when they realized I wasn't local (eg pick it up from them) they told me to go online and order it from their website and that it would be cheaper that way.

...And it was, saved me about $100!!

 

Sorry for reviving this thread just bought a 06 Mariner Hybrid with 101K with a cupped tire sound (whoop whoop whoop) plus a metallic rattle when driving. Dealership said bad transfer case and researching my options.

To the OP how is the used transfer case holding up?

 

Don't change the transfer case without changing the gear lube in it first. Save the drained fluid in a clear glass jar and see what come out. If it's relatively clear without metallic particles it's probably OK. The transfer case is actually a 90º gear unit that if its failling will eat itself up quickly. Otherwise they don't fail unless something causes a severe misalignment stress (low gear lube can cause a failure...).

I'd say the cupped tire stuff is likely a strut problem or worn ball joints in the steering setup. The rattle would not come from the transfer case unless it was going to fail in the next mile or so and then it would be a loud grinding type sound. Crawl around underneath and look for something loose. For example the sway bar can actually slid to one side and interfere with something, not likely but can happen.

 

Hey thanks but it has been in the shop waiting for my directions. After reading here and elsewhere about the typical sound of cans dragging under the car and a few mentioning the cup tire sound (could be tires too) I am at least confident this dealership is correct. The service writer said the TC was really low on fluid. I read a TCB that it is common for these to lose lubricant when the vent tube loosens up. I will try to get a better explanation if it can help someone else. I selected a used TC that they will get from a salvage yard.

 

yes mine experienced the rattling rocks in a can then aluminium grinding then loos of movement now replacement