Shari's 2009 Raliart

[blackrosenova400]

Fourth clue, you had to do a count before replacement.

[blackrosenova400]

Fourth clue, you had to do a count before replacement.

[blackrosenova400]

Ok no more clues.

Pulled the transfer case out slightly from the transmission and a pile of powdered rust fell out between the transmission and transfer case. Found the splines of the transmission and transfer case completely dogged and rusted out. There are multiple splines/teeth missing from the transfer case and transmission.

It appears here is supposed to be an o-ring on the transfer case housing to prevent water from contaminating the shafts, but the o-ring was not there. Since this is the first time it has been pulled on this car, it would appear this is an assembly fault by Mitsubishi.

Will get pictures soon.

[blackrosenova400]

http://www.mitsustyle.com/photopost/data/500/medium/CIMG2327.JPG

Here is where Mitsubishi neglected to install a 2$ o-ring to properly seal water/rust contamination.

http://www.mitsustyle.com/photopost/data/500/medium/CIMG2332.JPG

Here you can see the teeth heavily worn from rust on the t-case.

http://www.mitsustyle.com/photopost/data/500/medium/CIMG2325.JPG

Here there is a pile of powered rust. There is actually more than what the picture is showing.

There is alot more damage I cant get a good shot of at the moment. Specifically completlely missing teeth/splines.

Its all stripped out and the repair probably will require a new t-case and new front differnetial in the transmission.

[Kracka]

Oh man, that is no good :(

[Halon]

Who is doing the work on the car? Will Mitsu warranty it if they aren't the ones doing the work & finding the issue first hand?

[Kracka]

It's out of warranty, I think she told me 103k miles on Facebook.

[simulatedwood]

I am shocked it didn't leak, So bizzare.. Good news is you find a junk sst/ transfer case and you will be cooking with gas!

[blackrosenova400]

There are still oil seals on the transfer case and transmission to prevent oil leaking, but only that o-ring would have prevented water contamination between the transmission and t-case.

[scheides]

that is nuts! I've never seen that before to be honest. :(