I have a 08 CX-9 with ~75K miles. About a month ago, I heard a very loud POP while driving and at the next Signal I had noticeable Wheel-Spin during Acceleration. At the time, I did not equate the two and the vehicle did not show any other symptoms. Although the Wheel-Spin has continued, I have learned to compensate.
More recently, I was using a Cell-Phone Charger in the Center Console Power Port and I experienced an Airbag Fault Light. Again, I did not connect the Cell-Phone Charger to the Airbag Fault. However, I did research the Airbag Fault and discovered that it was a caused by the Cell-Phone Charger being connected to the Center Console Power Port (TSB-08-002/09). During this research, I also discovered SB-03-005/11 that addressed the Wheel-Spin during Acceleration.
After talking to the local dealer, finding out that any repair would not be covered under warranty, I started to investigate replacing the Transfer-Case myself. I am posting this because; some of you may find my research useful. (The dealer did supply me with a copy of TSB-03-001/12, which supersedes SB-03-005/11, I have attached that).SB-03-001-12a.pdf
Information on the CX-9 Transfer-Case indicates that:
Given the wide range of Ford vehicles that use the same Transfer-Case, I was very surprised to find that Ford Transfer-Cases do not suffer from the same failure as the Mazda units. The only TSB I could locate for the Ford units (TBS-09-25-07) is for a seal failure that causes leakage onto the exhaust manifold. Most likely, this was the change that was instituted on 08/08/08.
This led me to further investigate the interchangeability of the Ford for the Mazda Transfer-Case. Because, even if Ford has not fixed the leakage problem, it would be cheaper to repair the leak, than for the total replacement of the Mazda unit.
First I contacted Hollander, the company Auto Wreckers consult for the interchangeability of parts. They could confirm the interchangeability between Ford models or Mazda models. But, they could not confirm any interchangeability between Ford and Mazda models.
Then while searching eBay, I found the best clue. As the attached photo shows, the FORD P/N: 7E53-7251-BP WITH THE MAZDA P/N: AW21-27-500-H9U (a search of this number confirms that it is a valid CX-9 P/N) ETCHED INTO THE HOUSING OF THE TRANSFER-CASE. THIS WAS THE PROOF I WAS LOOKING FOR! FORD-MAZDA PN.JPG
I then looked at Ford P/Ns and how to decipher them, because Ford Codes information into their P/Ns. I found that there was a change in the Part Numbering System around 2000. This link will explain both systems: http://www.nospartsltd.com/Articles.asp?ID=250
This decoded the P/N as being for a 2007 Ford Fusion, not as a part for a Ford Edge. An eBay search for 7E53-7251-BP only returned the one exact listing, but did return several close listings for 7E5Z7251F. The 7E5Z7251F was listed a fitting 2011 & 2012 Ford Fusion (Model # E5), Ford/Lincoln Zephyr, Mercury Milan & Lincoln MKZ (Model # H6). Further research shows that this unit would fit 2007 thru 2012 model years. Please note that none of these models are not included in our earlier Ford Transfer-Case Interchangeability list for the Edge.
Maybe this reveals the heart of the problem. The Ford Fusion class of vehicle has a Curb Weight of ~3,300 lbs., while the CX-9 has a Curb Weight of ~4,500 lbs.
Is Transfer-Case chosen by Mazda is undersized for the weight of the vehicle?
Is Ford using Transfer-Case on the Edge that is stronger?
IT IS STILL UNKNOWN IF THE EDGE TRANSFER-CASE INTERCHANGEABLE WITH THE CX-9?
At this point, I need to decide whether to replace my Transfer-Case with a Mazda P/N: AW21-27-500K-9U and hope that it does not break again.
Or, try a Transfer-Case for a Ford Edge and hope that it is interchangeable.
That is the $600 question?
More recently, I was using a Cell-Phone Charger in the Center Console Power Port and I experienced an Airbag Fault Light. Again, I did not connect the Cell-Phone Charger to the Airbag Fault. However, I did research the Airbag Fault and discovered that it was a caused by the Cell-Phone Charger being connected to the Center Console Power Port (TSB-08-002/09). During this research, I also discovered SB-03-005/11 that addressed the Wheel-Spin during Acceleration.
After talking to the local dealer, finding out that any repair would not be covered under warranty, I started to investigate replacing the Transfer-Case myself. I am posting this because; some of you may find my research useful. (The dealer did supply me with a copy of TSB-03-001/12, which supersedes SB-03-005/11, I have attached that).SB-03-001-12a.pdf
Information on the CX-9 Transfer-Case indicates that:
- ALL CX-9s use the same Transfer-Case P/N: AW21-27-500K-9U.
- The Mazda CX-9 & the Ford Edge MAY use the same Transfer-Case.
- The Ford Edge Transfer-Case is also used in the Explorer, Flex, Taurus, Mercury Sable & Lincoln MKX.With interchangeability between all models from 2007 thru 2013.
- One website indicates a change in the Ford Transfer-Case on 08/08/08.(I would assume that Ford made that change to address a problem with the Transfer-Case).
Given the wide range of Ford vehicles that use the same Transfer-Case, I was very surprised to find that Ford Transfer-Cases do not suffer from the same failure as the Mazda units. The only TSB I could locate for the Ford units (TBS-09-25-07) is for a seal failure that causes leakage onto the exhaust manifold. Most likely, this was the change that was instituted on 08/08/08.
This led me to further investigate the interchangeability of the Ford for the Mazda Transfer-Case. Because, even if Ford has not fixed the leakage problem, it would be cheaper to repair the leak, than for the total replacement of the Mazda unit.
First I contacted Hollander, the company Auto Wreckers consult for the interchangeability of parts. They could confirm the interchangeability between Ford models or Mazda models. But, they could not confirm any interchangeability between Ford and Mazda models.
Then while searching eBay, I found the best clue. As the attached photo shows, the FORD P/N: 7E53-7251-BP WITH THE MAZDA P/N: AW21-27-500-H9U (a search of this number confirms that it is a valid CX-9 P/N) ETCHED INTO THE HOUSING OF THE TRANSFER-CASE. THIS WAS THE PROOF I WAS LOOKING FOR! FORD-MAZDA PN.JPG
I then looked at Ford P/Ns and how to decipher them, because Ford Codes information into their P/Ns. I found that there was a change in the Part Numbering System around 2000. This link will explain both systems: http://www.nospartsltd.com/Articles.asp?ID=250
This decoded the P/N as being for a 2007 Ford Fusion, not as a part for a Ford Edge. An eBay search for 7E53-7251-BP only returned the one exact listing, but did return several close listings for 7E5Z7251F. The 7E5Z7251F was listed a fitting 2011 & 2012 Ford Fusion (Model # E5), Ford/Lincoln Zephyr, Mercury Milan & Lincoln MKZ (Model # H6). Further research shows that this unit would fit 2007 thru 2012 model years. Please note that none of these models are not included in our earlier Ford Transfer-Case Interchangeability list for the Edge.
Maybe this reveals the heart of the problem. The Ford Fusion class of vehicle has a Curb Weight of ~3,300 lbs., while the CX-9 has a Curb Weight of ~4,500 lbs.
Is Transfer-Case chosen by Mazda is undersized for the weight of the vehicle?
Is Ford using Transfer-Case on the Edge that is stronger?
IT IS STILL UNKNOWN IF THE EDGE TRANSFER-CASE INTERCHANGEABLE WITH THE CX-9?
At this point, I need to decide whether to replace my Transfer-Case with a Mazda P/N: AW21-27-500K-9U and hope that it does not break again.
Or, try a Transfer-Case for a Ford Edge and hope that it is interchangeable.
That is the $600 question?