I'm at work now, so I will check this out tomorrow, one question though, if the transfer case does need to be replaced is this something I can do myself? Or does it require special tools that only dealers have.
I think it's doable if you have the right tools and have a high level of mechanical proficiency.
One of the Ford Edge guys was able to remove it and disassemble it himself and drill out his
own drain plug without any special dealer tools.
see Amazon link, looks pretty basic to install, looks like it's just bolted on , it's $553 shipped
https://www.amazon.com/dp/ (commissions earned)
read thru the Amazon questions link though, note one of the answered question
make sure to check the mating output splines from the transmission splines are not stripped
https://www.amazon.com/dp/ (commissions earned)
if the mating transmission splines are stripped and you install a brand new transfer case with perfect splines, the worn splines from the transmission will also wear out the new splines from the transfer case which will lead to premature transfer case failure.
That is why if you google CX-9 transfer cases, you'll find unfortunate owners who had to keep replacing transfer cases multiple times, some failed after 20k or less after a new transfer case was installed, it's because the transmission splines wasn't replaced.
See 67mgb post in link below,
http://www.mazdas247.com/forum/showthread.php?123831170-Transfer-case-SB-03-005-11&highlight=spline
THAT'S REALLY THE HEART OF THE CX-9 PTU issue, the PTU unit itself is relatively inexpensive, it's the collateral damage to the transmission splines that everyone is worried about, if you read 67mgb's post, if the transmission splines are damaged , they don't just sell that one little piece, the WHOLE TRANSMISSION has to be replaced and that is $$$$$.
Now here's the catch, the car will still run perfectly fine as a FWD, just not as a AWD. And that's why I think Mazda isn't issuing a full recall, it's not a life safety failure, the car can still be driven after a PTU failure but I'm pretty sure there will be a huge BANG sound, followed by violent jerking motion as the transmission and transfer case fight each and an awful putrid transfer case oil smell that would frighten most drivers.
Eventually the jerking will stop when the mating splines are completely sheared off and the transmission is decoupled from the PTU. Some owners may not want to spend that kind of money if the car can still run and just leave it alone and drive it as a FWD. For some that's just not an option and they need AWD in snow and just have to suck it up and fix it.
OR they cut their losses and trade it in or sell it. And unfortunately for the new buyers there's really no way to test the AWD until the first snowfall.
The splines get stripped if the PTU fails when the oil stops doing its job and the gears seize taking the transmission splines with it. That's why all the guys here on this forum are servicing the transfer case oil to prevent PTU failure but even more important; prevent $$$$$ transmission damage.