2011-2019 Dodge Journey Transfer Case: Noises, Leaks, and AWD Faults Explained

Symptoms of a Failing 2011-2019 Dodge Journey Transfer Case

A failing transfer case, or Power Transfer Unit (PTU), on a Dodge Journey will almost always provide audible or physical warnings. Ignoring these signs can lead to a complete failure of the AWD system or cause damage to other drivetrain components.

1. Whining, Grinding, or Growling Noises

The most common symptom is a noise from the center of the vehicle that sounds like grinding, whining, or a low growl. This noise is often speed-dependent, becoming louder as you accelerate. It can be caused by low fluid levels, which leads to poor lubrication of the internal gears and bearings, or by mechanical wear and damage inside the unit.

2. Clunking or Banging Noises

A loud clunk or bang, especially when shifting between Drive and Reverse or during sharp turns, points to a serious internal issue. This could be excessive play in the gears or, in severe cases, broken gear teeth. Some owners have reported loud banging noises from the rear when turning, which can be related to the viscous coupler on the rear differential, a component that works in tandem with the PTU.

3. Binding or Hopping During Turns

If you feel a shuddering, hopping, or binding sensation during tight, low-speed turns (like in a parking lot), it's a classic sign of transfer case or AWD system problems. This happens when the unit fails to allow for the necessary difference in speed between the front and rear axles during a turn, causing the driveline to bind up. It can feel as if the brakes are being lightly applied or that you're driving over a bumpy surface.

4. Fluid Leaks

Visible leaks of reddish-brown fluid on the ground beneath the middle of the car are a clear warning sign. The PTU has several seals (input shaft, output shafts) that can degrade over time and leak. Low fluid levels from a leak is a primary cause of internal damage due to lack of lubrication. Some owners report a burning oil smell accompanying the leak.

5. "Service AWD" Warning Light

The vehicle's computer monitors the AWD system. If it detects a fault, such as a failure to engage the rear wheels, it will illuminate a "Service AWD" or similar warning light on the dashboard. This often happens when the front wheels spin on a slippery surface, but the rear wheels fail to receive power.

Buying a Used Dodge Journey Transfer Case

Given the high cost of a new unit, a quality used OEM transfer case is often the most economical choice. Here’s what to look for to ensure you get a reliable part.

1. Physical Inspection

• Check the Housing: Carefully inspect the aluminum case for any cracks, fractures, or signs of heavy impact. Some failures involve the case itself cracking or breaking away from its mounting points.
• Turn the Shafts: The input and output shafts should rotate smoothly by hand without any grinding or notchiness. Significant resistance or rough spots indicate internal bearing or gear damage.
• Inspect the Seals: Look for obvious signs of leaks around the input and output shaft seals. While replacing seals on a used unit is good practice, heavy leaking on the donor part could suggest excessive wear.
• Look for Cleanliness: A unit caked in old, burnt fluid suggests a hard life and potential neglect. A relatively clean, low-mileage unit is always a better bet.

2. Mileage and Part Numbers

Mileage is a significant factor for a mechanical part with gears and bearings. Failures can occur at various mileages, with some reported as early as 60,000 miles and others lasting well over 100,000. Aim for the lowest mileage unit available. The OEM part numbers have been updated over time. The latest known part number is 68045780AD, which supersedes older versions like 68045780AA, 68045780AB, and 68045780AC. Always try to purchase the latest revision (AD) as it may contain internal improvements.

Cost of Replacing a Dodge Journey Transfer Case

The cost can vary significantly based on the part source and labor rates. A full replacement is almost always more practical than attempting a rebuild, as rebuild kits are not commonly available and the process requires specialized tools.

Known Issues, TSBs, and Recalls

While there are no specific recalls for the transfer case itself on 2011-2019 models, the Dodge Journey has numerous Technical Service Bulletins (TSBs). One relevant TSB for some model years notes that if the transmission bracket-to-case fasteners are removed during service, they are one-time use and must be replaced (Part Number 06511385A$). There are no widespread recalls directly targeting the PTU, but NHTSA has investigated the 2009-2020 Journey for other serious issues, including potential fire risk from electrical problems and faulty door locks.

Replacement and Installation Tips

Replacing the PTU is a moderately difficult job that can be done by an experienced DIY mechanic, but it requires proper tools and safety precautions.

• Fluid Type: While many Chrysler products use ATF+4 in the transfer case, service information for the Journey PTU often specifies a SAE 75W-90 Gear and Axle Lubricant. Always verify the correct fluid for your specific vehicle year before filling. Using the wrong fluid can cause damage.
• Sealant: A specific RTV sealant (Mopar 05010884AA or equivalent) should be applied to the new O-ring during installation to ensure a proper seal against the transaxle.
• Torque Specs: Using correct torque specifications is critical. While specs can vary slightly by year and specific bolt, general specs are:
  • PTU-to-transmission adaptor bolts: ~22 Nm (16 ft-lbs)
  • Driveshaft to PTU bolts: ~40 Nm (30 ft-lbs)
  • PTU drain/fill plugs: ~20 Nm (15 ft-lbs)
• Related Parts: It's wise to inspect the driveshaft U-joints and center support bearing for wear while the PTU is being replaced. Also, consider replacing the axle seal on the passenger side if it shows any signs of leaking.

Frequently Asked Questions (FAQ)