Noticing for a couple of months a burning smell coming into the car, at random times. Sometimes very strong, enough to have to drive with the windows down. Took into dealer and discovered the PTU (the thing off the transmission that powers the AWD) was leaking fluid, possibly dripping on exhaust causing the burning smell. Shop said parts inside were possibly worn or broken and the fluid was very burned. Covered under drive train warranty thank goodness. Surpised that something so major could be wrong with such a young vehicle that is well cared for.
I was changing my engine oil in my driveway, while waiting for the oil to drain completely, I noticed milky dark gray oily gunk behind or very close to my transmission. My suspicion was correct about the transfer case, or the PTU. I did not smell anything burning but fluid was covering spots under my car. Upon driving it another day or so, I had not noticed any performance issues, noises, smells, but I dropped it off at the dealer, and they give the diagnosis, $2000 to replace the transfer case. This is not under any sort of warranty and I am very upset this would happen at all. Ford should fix this COMMON issue, and recall their defective design.
I also experienced the burning odor and saw oil drips on garage floor and brought into dealership. They replace the gasket or seal on the PTU and this cost nearly $1000 for the seal plus a day of shop labor. When I was leaving I over hear another customer being told they had this issue also, this was after I was assured that this is uncommon issue. Disappointed to have such a major cost when this car had relatively low miles. This was 2 years ago and has been ok since.
Had odors of burning oil and a oil leak we could not find source, we were told by the people doing our service probably a minor thing as drivability was good. now at 135,000 miles they say transfer case was dry and unit is burned up. Also the transmission was banging real hard and bucking on attempts to pass and going uphill as well. My wife tells me about this after two weeks of driving like that. they tell me have to do transmission repair, over a valve body in transmission. they want $3500 to do these repairs. Then they hit me with it needs wheel bearings for a complete total of $4200 Transfer unit, transmission, and wheel bearings.
OK so then they call and want another $500 PLUS LABOR for new halfshafts, saying bearings are shot.
I said did you have to take that out to do estimated repairs already authorized, Yes, well then dont double dip me on LABOR, no way. extra for parts yes, no extra labor.
QUESTION; Is the estimated transmission and transfer case repair number of $3500 in the right range?