We own a 2007 Outback and had to replace the Head Gaskets 2 years ago with only 85,000 miles on the car for about $2200 (plus timing belt, etc. for a grand total of $3k).  Now less than two years later, with 111k miles, we are being told that the transfer case may need to be replaced based on the rattling sound under my hood, for another $2500-3000. What in the world?  This is our first Subaru and I am very disappointed. Is this normal?  Does this sound correct?  Is there something else that could be wrong?  Does anyone recommend getting a "used" transfer case if my mechanic can find one?  Any advice is much appreciated!

First off, Subarus do not have a "transfer case".  And if they are talking about the transmisson, which incorporates the AWD unit.......you wouldn't nessecarilly suspect any troubles form it to make a rattle under the hood........maybe a cracked flexplate, maybe.....

 

At any rate.

 

I would be skeptical of this diagnosis.

 

Definately take it to a independant subaru specialist.

Head gaskets are a normal replacement item on the engine in your car, though replacing them at 85k miles is a bit premature. Usually it's safe to wait until the first timing belt interval at 105k.

 

Someone had the sense to recommend replacing the belt while doing the head gaskets, which is good, but they may not have replaced all of the idler pulleys that guide the belt. There is one idler in particular that fails more often than the others, and it can make a rattle noise when it goes bad.

 

I agree you definitely need a second opinion from an independent Subaru shop.

Ya there is no conventional transfer case in your awd Subaru, if its an auto it has transfer clutches and firstly wouldn't be making a rattling noise under hood and shouldn't cost that much to replace or if its a stick it has a vicious center diff and still wouldn't make that noise or cost that much.