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While the premise of a vehicle with no steering wheel and no human driver is not something the motoring public is quite ready for, the case for Advanced Driver Assistance Systems (ADAS)
is strong.

In October, automaker Ford posted a third-quarter loss of $827 million, and said it was largely due to its self-driving tech partner Argo AI going under. That same month, J.D. Power and Associates released a study that showed consumer understanding of automated vehicles is rife with misinformation.

On paper, one can make a pretty practical case for autonomous driving – the most obvious benefit being that it could potentially increase road safety and eliminate traffic deaths. Additional justification lies in the ability to reduce collision insurance claims and increase independence for certain populations who are currently limited in their options for safe and reliable transportation – such as the elderly and disabled.

However, as real-world testing begins, the technology is encountering some pretty significant roadbumps, and consumer understanding of the technology isn’t belying the confidence to make the mass adoption of fully automated vehicles a realistic possibility any time soon.

The recent J.D. Power study found 65% of consumers surveyed were unable to accurately define fully automated, self-driving vehicles. Plus, 56% of respondents incorrectly classified the driver-assist technologies available today as fully automated, self-driving technologies. The survey hints that consumers are lagging in understanding as well as preparation for higher levels of automation.

The current system for classifying levels of automated driving was established by the Society of Automotive Engineers (SAE). Ranging from 0-5, the SAE levels run the gamut from Level 0 where the driver is fully responsible for the vehicle’s operation and supervision of the technology on the car at all times, to Level 5, which gives complete control of the vehicle to the operating system itself and requires no human supervision at all. At this time, there are no Level 3-5 autonomous vehicles on the road today, according to J.D. Power.

Today, the most widely used safety technology on vehicles on roads today would be considered Level 2 – which would include such things as Advanced Driver Assistance Systems (ADAS) – automatic emergency braking (AEB), and Electronic Stability Control (ESC), lane assist, parking assist, driver drowsiness detection, gaze detection, etc. These technologies provide partial automation by taking over control in specific situations – such as turning a corner too fast, or coming to close to a vehicle in front of you. In 2008, ESC systems became mandated by NHTSA on all new vehicles by 2011. All automakers are currently participating in a voluntary commitment to make AEB standard on all vehicles as well.

In a recent webinar hosted by Reason Foundation, Brookings Institution and Princeton Autonomous Vehicle Engineering, several experts on AVs shared their thoughts on the subject, hoping to correct some of the common misconceptions and inject a dose of realism into the public debates surrounding autonomous vehicle technology. One of the three speakers, Alan Kornhauser, professor, Operations Research and Financial Engineering, and faculty chair of Autonomous Vehicle Engineering at Princeton University, said he believes ADAS should be mandated.

“ADAS is focused purely on safety,” said Kornhauser. “It’s on all the time, and it overrides drivers only to avoid getting into a crash situation. We’ve had a number of these systems in our vehicles for a long time. As long as we’re not using the brakes inappropriately, they just work the way we want. Otherwise, the system takes over and doesn’t allow you to lock your wheels. Same thing with electronic stability control. You can go around corners just fine. You go around too fast, all of a sudden, the system takes over and makes sure that you don’t lose your rear end. And maybe one of the most successful of these systems is reverse automated braking systems so that if you back up and there happens to be a child behind your car, the car stops.

“This has enormous implication on insurance because in fact, if there is no crash, then there’s no insurance that needs to be paid out. There’s no lawyer, there’s no ambulance, there’s no medical payments that have to be paid,” Kornhauser added.

When it comes to seeing federal or state regulations that could pave the way for more fully autonomous (i.e., driverless) cars on the road, Marc Scribner, senior transportation policy analyst at Reason Foundation, believes we aren’t quite there yet. Having consistent, published technical standards may be one of the bigger roadblocks, he said.

“Automated vehicle regulation is not going to occur in the near term,” said Scribner. “I think the delay is, in part, due to the lack of published voluntary consensus standards that may be ripe for regulatory incorporation. But, there also seems to be generally, at least so far [in] this administration, perhaps less enthusiasm for automated driving systems than the previous two administrations. But, I do think the lack of published technical standards that could be incorporated into regulation is a hurdle. Where federal regulators are silent, states may act instead. States and locals have primary authority over vehicle operations and infrastructure management. They own the roads; they manage the roads. They license drivers, they register vehicles. All of that kind of thing goes in with the vehicles actually out there in the real world,” said Scribner.

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    • By GreenGears Auto Limited
      Published by GreenGears Auto  |  9 minute read  |  Transfer Case Reliability & Buyer's Guides
      Not all used transfer cases are created equal. Some units are engineered so conservatively that they routinely exceed 200,000 miles with minimal intervention. Others are mechanically complex enough that a single neglected service interval can cause irreversible damage. Knowing which transfer case units have earned a genuine reputation for long-term reliability — and why — is the difference between a great used part purchase and an expensive repeat repair. At GreenGears Auto, we've sourced, inspected, and sold used transfer cases across every major make and platform. This guide ranks the most reliable used transfer case units on the market, based on engineering design, real-world longevity data, and what we see in our own inspections every day.    
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      Reliability in a transfer case comes down to a consistent set of engineering and design factors. Understanding these helps explain why certain units appear repeatedly in high-mileage vehicles — and why others fail at predictable intervals.
        ⚙️Mechanical Simplicity Fewer moving parts means fewer failure points. Gear-driven transfer cases outlast chain-driven units under equivalent conditions. Units with no electronic shift components have no electronic failure modes — and are often the longest-lived designs in the used market.
        🔩Conservative Design Margins The most reliable transfer cases are significantly over-engineered for their actual application. Toyota, BorgWarner heavy-duty, and Dana units in particular are rated well above the torque levels they routinely see — giving them long fatigue lives even under hard use.
        💧Fluid Tolerance Some transfer case designs are forgiving of extended fluid change intervals; others are extremely sensitive to fluid degradation. Units that can tolerate modest fluid neglect without catastrophic damage are inherently more reliable in the used market — where maintenance history is not always known.
        🏭OEM Supplier Quality BorgWarner, Dana, Magna, and NVG (New Venture Gear) are the primary OEM transfer case manufacturers. BorgWarner's heavy-duty and automotive-grade units consistently rank among the most durable. Dana units in Jeep and truck applications are legendary for load tolerance.
        📋Proven Service Record The best indicator of reliability is real-world longevity across millions of vehicles. Units that have demonstrated 150,000–250,000-mile service lives across diverse operating conditions — not just ideal ones — earn their reputations. The units in this guide have all earned theirs.
        🔄Availability of Quality Used Units A reliable transfer case that fails early or rarely enters the salvage market as a high-quality used part. The units in this guide combine high inherent reliability with sufficient production volume that quality used examples are accessible — the combination that makes them genuinely worth sourcing.
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        1- 🏆 Most Reliable Overall Toyota / Lexus 4WD Transfer Case (4Runner, Land Cruiser, Sequoia, Lexus GX)
      Typical Used Price: $320–$720 ⭐⭐⭐⭐⭐ Reliability Rating Toyota's 4WD transfer cases are the undisputed reliability benchmark in the used transfer case market. The 4Runner's 2-speed part-time unit — used across the 4th gen (2003–2009) and 5th gen (2010–present) — is engineered with load margins that make catastrophic failure under normal use virtually unknown. The Land Cruiser's full-time centre differential transfer case takes this further — it is built to Toyota's most demanding specifications and is routinely found in working condition on 300,000-mile vehicles.
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      🔧 Best Specific Unit to Source The 4th gen Toyota 4Runner (2003–2009) transfer case is the sweet spot in the Toyota used market — wide availability, proven 200,000-mile reliability track record, simple electronic shift design, and competitive pricing. It is consistently one of the highest-quality used transfer case purchases available regardless of make or model.   2- 💪 Most Durable Heavy-Duty Unit BorgWarner NP261 / NP263 (GM Full-Size Trucks & SUVs)
      Typical Used Price: $380–$720 ⭐⭐⭐⭐⭐ Reliability Rating BorgWarner's NP261 and NP263 transfer cases — fitted to full-size GM trucks and SUVs from 2001 through 2013 — are among the most respected heavy-duty transfer case units in the US market. The NP263 in particular, with its higher torque capacity and updated internals over the NP261, is specifically engineered for the demands of three-quarter and one-ton truck applications — which means it is substantially over-engineered for the Tahoe and Suburban applications where it is most commonly encountered as a used unit.
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      Typical Used Price: $280–$650 ⭐⭐⭐⭐⭐ Reliability Rating The Dana 300 is one of the most celebrated transfer case designs in off-road history — a gear-driven, two-speed unit with an exceptionally low 2.61:1 low-range ratio that provides outstanding crawl capability without the fragility that characterises many complex designs. Dana Spicer's later units fitted to Jeep Grand Cherokee and Commander platforms continue this heritage of robust, over-engineered design that prioritises mechanical integrity over electronic sophistication.
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      Gear-driven design — no chain to stretch or replace; gear sets last the life of the vehicle under normal use with correct fluid maintenance Exceptionally low-range crawl ratio — the 2.61:1 low range provides genuine off-road capability that most competitors' chain-driven units cannot match Dana's reputation for load tolerance — Dana axle and transfer case components are consistently over-engineered relative to rated capacity; real-world durability exceeds specifications Massive enthusiast and rebuild support ecosystem — Dana 300 rebuild kits, replacement gears, and upgraded components are widely available; a worn unit can be restored to like-new condition Simple design philosophy — Dana prioritises mechanical robustness over feature complexity; fewer components means fewer things to fail Vehicles fitted: Jeep CJ-7 (Dana 300), Jeep Wrangler YJ / TJ (Dana 300 aftermarket / Selec-Trac NP231), Jeep Grand Cherokee WJ/WK (Selec-Trac NV242, Quadra-Trac NV247), Jeep Commander
        4- 🔩 Best High-Volume AWD Unit BorgWarner 13-54 / 44-06 (Ford F-150, Expedition, Explorer)
      Typical Used Price: $380–$750 ⭐⭐⭐⭐ Reliability Rating BorgWarner's 13-54 and 44-06 transfer cases — fitted to the Ford F-150, Expedition, Explorer, and Lincoln Navigator — represent the best combination of reliability, availability, and value in the used AWD/4WD transfer case market. The sheer volume of these units in the US vehicle fleet creates an exceptional used parts supply that keeps quality units available at competitive prices. These are proven 150,000-mile units when fluid is maintained.
      Why it ranks fourth:
      BorgWarner chain-driven design has a proven 15+ year track record across millions of F-150 and Expedition vehicles — real-world longevity data is extensive and well-documented Electronic shift encoder motor is a separately replaceable component — a failed motor does not require full unit replacement and should not disqualify an otherwise healthy case Fluid maintenance is the primary determinant of longevity — properly maintained units routinely reach 150,000–180,000 miles without internal mechanical failure Outstanding parts and rebuild support — BorgWarner 44-06 rebuild kits, chain and sprocket sets, and seal kits are widely and affordably available Massive used parts supply from the enormous F-150 and Expedition fleet — the most available and competitively priced full-size truck transfer case unit in the US market Vehicles fitted: Ford F-150 4WD (2004–2020), Ford Expedition 4WD (2007–2020), Ford Explorer AWD (2011–2019), Lincoln Navigator 4WD, Lincoln Aviator
        5- ⚙️ Most Reliable Crossover AWD Subaru Symmetrical AWD Centre Differential (Outback, Forester, Legacy)
      Typical Used Price: $240–$540 ⭐⭐⭐⭐ Reliability Rating Subaru's Symmetrical AWD centre differential unit is the most mechanically elegant AWD transfer case design in the mass-market vehicle segment. Unlike the bolt-on transfer cases used on transverse-engine AWD platforms, the Subaru unit is an integral part of the transmission's output — a viscous-coupling or Torsen-based centre differential that manages front-to-rear torque distribution continuously without electronics or actuators. This simplicity is the source of its exceptional reliability.
      Why it ranks fifth:
      Viscous centre differential design has virtually no electronic components — no solenoids to fail, no encoders to wear, no actuators to seize; the mechanical design is self-contained and inherently durable Subaru's longitudinal AWD layout means the centre differential operates at driveshaft speed rather than wheel speed — significantly lower rotational stress than bolt-on crossover transfer cases High production volume across the Outback, Forester, Legacy, and Impreza platforms creates excellent used parts availability at very accessible prices Strong maintenance record among Subaru owners — the brand attracts owners who tend to follow service schedules, meaning used units often come from well-maintained donor vehicles Subaru AWD is standard-equipment on most trims, not an upgrade — virtually every Subaru in the used market has the AWD unit, creating high supply volume Vehicles fitted: Subaru Outback AWD (2005–present), Subaru Forester AWD (2003–present), Subaru Legacy AWD, Subaru Impreza AWD, Subaru Crosstrek AWD
      ⚠️ Subaru Tire Matching — Non-Negotiable Subaru's centre differential is exceptionally reliable — but it is sensitive to tire diameter mismatches. All four tires must be within 1/4 inch of the same circumference. Operating with mismatched tires forces the centre differential to compensate continuously, accelerating wear and causing premature failure. Always verify tire matching before and after installing a Subaru transfer case unit.   6- 🚗 Best Compact Crossover AWD Toyota RAV4 Active Torque Control (ATC) / Honda CR-V Rear Drive Unit (RDU)
      Typical Used Price: $180–$460 ⭐⭐⭐⭐ Reliability Rating The Toyota RAV4's Active Torque Control (ATC) transfer case and Honda's CR-V Rear Drive Unit (RDU) are the two most reliable on-demand AWD transfer case designs in the compact crossover segment. Both are electronically controlled units designed to engage rear-wheel drive only when wheel slip is detected — keeping parasitic drag low during normal driving while delivering AWD capability when needed. Both benefit from the enormous sales volumes of their respective platforms, creating outstanding used parts availability.
      Why it ranks sixth:
      Toyota RAV4 ATC: Conservative BorgWarner-supplied electronically controlled unit; designed for low engagement frequency which reduces wear compared to full-time AWD units; 2013–2022 units have an outstanding reliability track record across millions of vehicles Honda CR-V RDU: Honda's dual pump system design is mechanically simple and highly tolerant of extended service intervals; among the most affordable quality used AWD transfer case units in the entire market Both units benefit from high sales volumes — RAV4 is America's best-selling SUV, CR-V is consistently in the top three; used parts supply is exceptional On-demand design means lower average operating stress than full-time AWD units — these units spend most of their service life in a disengaged or lightly loaded state Fluid maintenance is straightforward and infrequent relative to more complex systems — contributing to the better-than-average used market condition of these units Vehicles fitted: Toyota RAV4 AWD (2013–2022), Toyota Highlander AWD (2008–2020), Honda CR-V AWD (2012–2022), Honda Passport AWD, Honda Pilot AWD
        7- 🔄 Best Performance AWD Unit Nissan ATTESA E-TS / Infiniti AWD Transfer Case (Armada, Pathfinder R51, QX)
      Typical Used Price: $300–$640 ⭐⭐⭐⭐ Reliability Rating Nissan's ATTESA E-TS (Advanced Total Traction Engineering System for All-terrain with Electronic Torque Split) is one of the most sophisticated and durable AWD transfer case designs offered in mainstream vehicles. Originally developed for the Skyline GT-R, the road-going version fitted to the Armada, older Pathfinder, and Infiniti QX platforms represents a genuinely over-engineered unit that delivers both performance and durability far beyond what most owners demand of it.
      Developed from Nissan's motorsport AWD technology — load ratings exceed typical SUV demands by a significant margin Electronic torque split management is highly reliable — Nissan's proprietary AWD controller has an excellent track record across decades of production Body-on-frame Armada / QX80 platform means the transfer case operates in a well-supported structural environment with good thermal management Cross-references with Titan pickup transfer cases — expands sourcing options when Armada-specific units are not immediately available Infiniti QX donor vehicles typically have significantly lower mileage and better documented service histories than Armada equivalents Vehicles fitted: Nissan Armada (2004–present), Nissan Pathfinder body-on-frame (R50, 1996–2004), Infiniti QX56 / QX80 (2004–present), Infiniti QX4
       
      Reliability Rankings at a Glance
      Rank Transfer Case Unit Key Vehicles Used Price Reliability Availability #1 Toyota 4WD / Land Cruiser 4Runner, Land Cruiser, Sequoia $320–$720 ⭐⭐⭐⭐⭐ ⭐⭐⭐⭐⭐ #2 BorgWarner NP261 / NP263 GM Silverado HD, Tahoe, Suburban $380–$720 ⭐⭐⭐⭐⭐ ⭐⭐⭐⭐⭐ #3 Dana 300 / Dana Spicer Jeep Wrangler, Grand Cherokee $280–$650 ⭐⭐⭐⭐⭐ ⭐⭐⭐⭐ #4 BorgWarner 13-54 / 44-06 Ford F-150, Expedition, Explorer $380–$750 ⭐⭐⭐⭐ ⭐⭐⭐⭐⭐ #5 Subaru Symmetrical AWD Outback, Forester, Legacy $240–$540 ⭐⭐⭐⭐ ⭐⭐⭐⭐⭐ #6 Toyota ATC / Honda RDU RAV4, Highlander, CR-V, Pilot $180–$460 ⭐⭐⭐⭐ ⭐⭐⭐⭐⭐ #7 Nissan ATTESA E-TS Armada, Pathfinder, Infiniti QX $300–$640 ⭐⭐⭐⭐ ⭐⭐⭐⭐  
       
       
      How to Verify Reliability When Buying Used
      Even the most reliable transfer case unit can be damaged by neglect, misuse, or a difficult service history. Here is what to check before purchasing — regardless of the unit's inherent reliability ranking.
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      Drain and inspect the fluid before committing to any used transfer case purchase. Clean amber or light brown fluid with no metallic debris confirms a well-maintained unit. Dark, burnt, or metal-laden fluid tells you this unit has been stressed beyond its design intent — regardless of how low the odometer reads. Milky or foamy fluid indicates water contamination and is a hard disqualifier on even the most reliable platform. Confirm Donor Mileage and Use Context
      A Toyota 4Runner transfer case from a 60,000-mile highway-driven donor is a fundamentally better purchase than the same unit from a 60,000-mile trail-driven and towing-heavy example. Both mileage and use context matter. GreenGears Auto documents both donor mileage and — where available — use context on every listing. Inspect All Housing Surfaces
      Even the most reliable transfer case housing can be cracked by a severe impact. Inspect all external surfaces, paying particular attention to the bottom of the case (most vulnerable to ground strikes), the mating surfaces between case halves, and the area around the drain and fill plugs. A cracked housing is disqualifying — it cannot be reliably sealed under operating conditions. Check Electronic Components Independently
      For units with electronic shift motors or AWD solenoids (BorgWarner 44-06, Toyota ESOF, Nissan ATTESA), inspect the electrical components separately from the mechanical assembly. A failed encoder motor on an otherwise perfect BorgWarner unit is a $100–$150 repair — it should not disqualify the purchase or inflate the price. Know what you're buying. Verify All Seals Before Installation
      Plan to replace all input and output shaft seals on every used transfer case regardless of their apparent condition. Seal replacement costs $30–$90 in parts and is far cheaper than removing and reinstalling the unit after a seal-related leak. For Ford PTU units specifically, also replace the vent tube — a blocked vent is the single most common cause of PTU seal failure.  
       
      OEM Used vs. Remanufactured — Which Is the Better Reliability Choice?
       
      🏭 Remanufactured Units
      Cost: $700–$2,000 + core charge of $200–$600 Electronic components (solenoids, encoders) frequently reused from worn cores — the most common post-install failure source Rebuild quality entirely dependent on the rebuilder — no standardised quality assurance across suppliers Some reman units use reconditioned chains, bearings, and clutch packs that may not match OEM specifications Factory ECU calibration is lost — calibration to vehicle's AWD system not guaranteed Core charge creates upfront cost burden and logistical complexity  
      ♻️ OEM Used — GreenGears Auto
      Cost: $180–$750 — no core charge, no deposit Original factory electronic components — no reused worn solenoids or encoders Original factory assembly with original tolerances and material specifications Original chain, bearings, and gears — condition verified pre-sale, not rebuilt to variable quality Factory ECU calibration intact — correct AWD system integration from day one Free US shipping in 3–7 days & 15 to 90-day satisfaction guarantee  
       
      Getting the Most Life from Your Used Transfer Case
      Even a highly reliable used transfer case will underperform its potential if installation and initial service are handled incorrectly. These are the non-negotiable steps for maximising service life from any used unit.
      Replace all input and output shaft seals at installation — the most reliable units in this guide will develop leaks from compromised seals within 20,000–40,000 miles if seals are not replaced at installation Fill with the exact manufacturer-specified transfer case fluid — never substitute generic ATF, gear oil, or a "universal" fluid; Toyota, Subaru, Honda, GM, and Ford all specify proprietary fluids for their transfer cases and the wrong fluid causes rapid internal wear Change the fluid immediately after installation on any used unit — flush the system with fresh fluid to remove any residual debris before the unit enters service in your vehicle Follow the manufacturer's severe-duty fluid change interval if the vehicle is used for towing, off-road driving, or regular winter operation — typically 30,000 miles; standard interval is 60,000 miles Clear all drivetrain, AWD, traction control, and ABS fault codes after installation and perform a test drive across all modes before returning the vehicle For vehicles with ADAS features, confirm all drivetrain fault codes are fully resolved — active drivetrain faults can suppress ADAS functions on some platforms On BorgWarner ESOF units (Ford, GM), test the encoder motor function across all modes — 2H, 4H, 4L — before completing the repair; encoder motor failures are far cheaper to address with the unit accessible  
      ✅ The GreenGears Auto Inspection Standard Every transfer case in our inventory — regardless of platform or price point — is inspected for fluid condition, housing integrity, electronic component status, seal condition, and documented donor mileage before listing. We back every unit with our 90-day satisfaction guarantee, free US shipping, and no core charge. Our goal is simple: you get a reliable unit the first time, every time.    
      Looking for a Reliable Used Transfer Case?
      Tell us your year, make, model, and drivetrain — our transfer case specialists will locate the right inspected OEM unit from our inventory and get it to you in 2–3 days with free US shipping.
      GreenGears Auto — Drive Green. Drive Smart.
      ✅ 6-Point Inspection 🚚 Free US Shipping ↩️ 15-Day Returns 📋 No Core Charge link hidden, please login to view
    • By GreenGears Auto Limited
      Published by GreenGears Auto  |  9 minute read  |  AWD Drivetrain & Transfer Case Guides
       
      The transfer case is the unsung hero of every AWD system. While most drivers associate all-wheel drive with traction and safety, few realize the transfer case is the component making it all possible — splitting torque between axles, managing engagement timing, and coordinating with stability and traction control systems in real time. When it fails, your vehicle loses its AWD capability entirely. New OEM transfer cases cost $900–$3,200+ depending on the platform. At GreenGears Auto, we stock inspected OEM used transfer case assemblies sourced from low-mileage donors across every major AWD platform — at 50–70% less than new pricing. This guide covers every major make, what makes each unit unique, and how to source correctly.    
      How AWD Transfer Cases Differ from 4WD Units
      Transfer cases in AWD vehicles operate very differently from the part-time 4WD units found in body-on-frame trucks. Understanding the distinction is critical when sourcing a replacement — and explains why OEM fitment is non-negotiable on modern AWD systems.
        🔄Full-Time AWD (Active) The transfer case continuously distributes torque front-to-rear without driver input. Uses a center differential or electronically controlled clutch pack to manage split ratios in real time based on wheel slip, vehicle speed, and steering angle. Found on most modern crossovers and luxury SUVs.
        ⚡On-Demand AWD (Reactive) The vehicle normally drives the primary axle only. The transfer case detects wheel slip and engages the secondary axle electronically when needed. Lower parasitic drag improves fuel economy. Common on Honda CR-V, Toyota RAV4, Ford Escape, and similar crossovers.
        🧠Torque Vectoring AWD The most sophisticated type — the transfer case actively varies torque distribution left-to-right across an axle, not just front-to-rear. Found on performance AWD systems like Acura SH-AWD, BMW xDrive M variants, and Porsche PTM. Requires exact OEM replacement for correct operation.
        🔧 GreenGears Tip — Why AWD Transfer Case OEM Sourcing Matters More Than 4WD AWD transfer cases are deeply integrated with a vehicle's ABS, stability control, traction control, and in newer vehicles, ADAS systems. An incorrect or aftermarket unit introduces calibration errors that trigger fault codes, compromise safety system function, and in some cases prevent the vehicle from passing an emissions or inspection test. OEM used is the only reliable option for modern AWD applications.    
      Warning Signs of a Failing AWD Transfer Case
      AWD transfer case failures are often misdiagnosed as differential, driveshaft, or traction control faults. Knowing the specific symptom patterns helps confirm the diagnosis before ordering a replacement unit.
       
      🔊 Noise Symptoms
      Grinding or humming that changes with vehicle speed Whining in AWD mode that disappears in 2WD (if selectable) Clunking during acceleration or deceleration Vibration through the floor at highway speed Chain rattle from the transfer case area at startup  
      ⚡ Warning Light & Electronic Symptoms
      AWD, 4WD, or All-Wheel Drive warning light illuminated Traction control or stability control fault codes AWD system disabled message on instrument cluster ABS fault codes appearing alongside AWD codes Intermittent AWD engagement — system cuts in and out  
      🔩 Handling & Drivability
      Loss of traction on wet or slippery surfaces where AWD previously helped Binding or tight steering — especially in tight turns Uneven power delivery front-to-rear under acceleration Vehicle pulls to one side during AWD engagement Shudder during cornering at low speed  
      💧 Fluid & Leak Symptoms
      Transfer case fluid puddle under the center of the vehicle Burnt or dark transfer case fluid on inspection Metal particles visible in drained fluid Low fluid level with no visible external leak (internal seal failure) Milky or foamy fluid indicating water contamination  
       
      Top OEM Transfer Case Assemblies by AWD Platform
      Here is a make-by-make breakdown of the most commonly needed and best-value OEM used transfer case assemblies across every major AWD vehicle platform.
       
      🏆 Best Overall Reliability Toyota / Lexus AWD
      Toyota RAV4 / Highlander / 4Runner / Lexus RX — Transfer Case Assembly
      Typical Used Price: $280–$620 Toyota's AWD transfer case assemblies are among the most reliable and widely available in the used OEM market. Toyota's conservative engineering approach — favouring proven mechanical designs over complex electronics — produces transfer cases with very low intrinsic failure rates. When they do fail, it's almost always fluid-related. The enormous volume of Toyota and Lexus AWD vehicles in the US market ensures outstanding used parts availability at competitive pricing.
      RAV4 AWD (2013–2022): Active Torque Control (ATC) transfer case — compact, electronically controlled, and exceptionally reliable; highest availability of any Toyota AWD transfer case RAV4 Dynamic Torque Control (2019–Present): Advanced unit with rear axle disconnect capability — confirm generation before ordering as it is not compatible with earlier units Highlander AWD (2008–2020): BorgWarner-supplied transfer case in most generations; robust unit with strong used market availability from high-volume Highlander sales 4Runner / FJ Cruiser (2003–2014): Part-time 4WD with 2-speed transfer case — simple, overbuilt, extremely long-lived; used units from low-mileage highway donors are outstanding buys Lexus RX 350/450h AWD: Shares transfer case architecture with the Highlander; Lexus donor vehicles tend to have lower mileage and better maintenance histories   ⚙️ RAV4 Hybrid AWD Note The RAV4 Hybrid and RAV4 Prime use an electric motor to drive the rear axle — there is no mechanical transfer case or driveshaft. These are not transfer case applications. Confirm you have a conventionally powered AWD RAV4 before sourcing a transfer case unit.  
      ⚙️ Most AWD-Committed Platform Subaru Symmetrical AWD
      Subaru Outback / Forester / Impreza / WRX — Transfer Case / Centre Differential
      Typical Used Price: $240–$580 Subaru's Symmetrical AWD is unique among mass-market AWD systems — it uses a longitudinally mounted engine and transmission that allows a true centre differential-based transfer case rather than the bolt-on transfer cases common on transverse-engine platforms. Every Subaru AWD model has a transfer case integrated into or directly adjacent to the transmission, making it the most drivetrain-specific replacement in this guide.
      Outback / Forester / Impreza (non-STI): Viscous centre differential transfer unit — simple, reliable, and well-priced in the used market; 2010–2019 units are the most available WRX (2008–Present): Active Torque Split AWD transfer unit with electronically managed distribution; WRX-specific sourcing required — do not substitute Outback units WRX STI: Driver-Controlled Centre Differential (DCCD) — the most sophisticated Subaru AWD transfer unit; used STI DCCD units command a significant premium due to high demand and low supply Crosstrek AWD: Shares Impreza transfer case architecture — expanding sourcing options; 2018–2023 units are increasingly available   ⚠️ Subaru Tire Diameter Warning All four tires on a Subaru AWD vehicle must be within 1/4 inch of the same diameter. Mismatched tires force the centre differential to compensate continuously — accelerating wear and causing the same symptoms as a failing transfer case. Before replacing a Subaru transfer case, always verify all four tires are correctly matched.  
      💰 Best Value Crossover Honda / Acura AWD
      Honda CR-V / Pilot / Passport / Acura MDX / RDX — VTM-4 / SH-AWD Transfer Case
      Typical Used Price: $220–$560 Honda and Acura's AWD systems span two distinct designs — the Variable Torque Management 4WD (VTM-4) system used on the Pilot and older MDX, and the electronically controlled on-demand AWD used on the CR-V, Passport, and newer RDX. Both produce excellent used OEM transfer case availability thanks to Honda's high sales volume across all platforms.
      Honda CR-V AWD (2012–2022): Rear drive unit (RDU) — Honda's term for the transfer case coupling unit; compact, reliable, and among the most affordable AWD transfer case units in the used market Honda Pilot AWD (2016–Present): Intelligent Variable Torque Management (i-VTM4) — more sophisticated than the CR-V unit; electronically controlled multi-plate clutch pack transfers up to 70% of torque rearward Acura MDX SH-AWD (2014–Present): Super Handling AWD transfer unit with left-right rear torque vectoring capability; OEM used units are the only viable replacement option — aftermarket units for SH-AWD do not exist in meaningful supply Acura RDX AWD (2019–Present): Updated SH-AWD architecture with faster torque response; sourcing availability building as the fleet ages  
      🔩 Best for American Crossovers Ford / Lincoln AWD
      Ford Escape / Edge / Explorer / Lincoln MKC / Nautilus — PTU / Transfer Case Assembly
      Typical Used Price: $260–$680 Ford's AWD crossovers use a Power Transfer Unit (PTU) — Ford's terminology for the transfer case on transverse-engine AWD platforms. The PTU is mounted to the front transaxle and drives the rear axle via a prop shaft. It is one of the most commonly replaced drivetrain components on Ford's crossover lineup — largely because early PTU designs were prone to seal failure that led to fluid loss and internal damage when not caught promptly.
      Ford Escape AWD (2013–2019): PTU is the single most commonly replaced drivetrain component on this platform; seal failure is the primary cause — always replace the PTU seals when installing a used unit Ford Edge AWD (2011–2018): Larger PTU than the Escape; 2015–2018 units are the most available and best-priced Ford Explorer AWD (2011–2019): PTU carries higher torque loads than the Edge or Escape; sourcing from Explorer towing-spec donor vehicles adds confidence in load capacity Lincoln MKC / Nautilus / MKX: Share PTU architecture with the Escape, Edge, and Explorer respectively — Lincoln donor vehicles typically have lower mileage and better service histories   ⚠️ Ford PTU Seal Failure — Critical Installation Note The most common failure mode for Ford AWD PTUs is seal failure leading to fluid loss. A used PTU in otherwise good condition installed without new seals will frequently develop the same leak within 20,000–40,000 miles. Always install a complete PTU seal kit ($40–$80) alongside any used Ford PTU — this single step dramatically extends the service life of the replacement unit.  
      💪 Best for Full-Size AWD GM / Cadillac AWD
      Chevrolet Equinox / Traverse / Cadillac XT5 / SRX — Transfer Case Assembly
      Typical Used Price: $300–$720 General Motors uses electronically controlled transfer case assemblies across its AWD crossover and SUV lineup. The units fitted to the Equinox, Traverse, and Cadillac XT5 are BorgWarner-supplied designs with electronically managed clutch packs that provide seamless on-demand AWD engagement. GM's enormous sales volume ensures excellent used parts availability across all generations.
      Chevrolet Equinox AWD (2010–2017): BorgWarner electronic transfer case — compact, well-priced, and widely available; 2013–2017 units are the best combination of reliability and used market availability Chevrolet Traverse / Buick Enclave AWD (2009–2017): Larger BorgWarner unit than the Equinox; shares architecture across Traverse, Enclave, and Acadia — broadens sourcing options Cadillac XT5 / SRX AWD: Same BorgWarner architecture as the Equinox/Traverse family with Cadillac-specific calibration; Cadillac donor vehicles have lower average mileage — worth seeking out for quality Chevrolet Traverse / GMC Acadia (2018–Present): Updated BorgWarner unit with improved torque distribution; increasingly available as this generation enters the higher-mileage salvage market  
      🇩🇪 European Precision AWD BMW xDrive
      BMW X3 / X5 / 3 Series / 5 Series xDrive — ATC / ATC700 Transfer Case
      Typical Used Price: $420–$950 BMW's xDrive AWD system is one of the most capable and most repair-intensive AWD platforms in the used market. The xDrive transfer case — branded as the ATC (Active Transfer Case) — uses an electronically controlled multi-plate wet clutch to manage torque distribution between the front and rear axles. It communicates directly with the DSC (Dynamic Stability Control), ABS, and — on M models — the Active M Differential. OEM used is the only viable replacement pathway at a sensible cost.
      BMW X3 (F25, 2011–2017): ATC 35L transfer case — the most commonly available BMW xDrive transfer case unit; well-priced relative to new cost BMW X5 (E70, 2007–2013): ATC 700 transfer case — larger unit for the full-size X5; 3.0i and 4.8i variants use the same unit, simplifying sourcing BMW X5 (F15, 2014–2018): Updated ATC design with improved efficiency; increasingly available from accident donors BMW 3 Series / 5 Series xDrive: Compact ATC unit designed for the sedan and wagon platforms; shares architecture with the X3 on many model years   💡 BMW xDrive Transfer Case Coding After installing a used xDrive ATC unit, BMW requires the replacement to be coded to the vehicle using BMW ISTA+ or ENET diagnostic software. Without coding, the xDrive system may default to a limp mode with limited rear torque distribution. Factor dealer or independent BMW shop coding time into your total repair budget.  
      🇩🇪 4MATIC Specialist Mercedes-Benz 4MATIC
      Mercedes GLE / GLC / C-Class / E-Class 4MATIC — Transfer Case Assembly
      Typical Used Price: $480–$1,100 Mercedes-Benz 4MATIC systems use a transfer case integrated with the transmission on most platforms — on the 7G-Tronic and 9G-Tronic automatic transmission families, the transfer case is a bolt-on rear output unit that can be serviced independently. Mercedes 4MATIC transfer cases are among the most expensive to replace new, making OEM used sourcing particularly compelling on these vehicles.
      GLC 300 4MATIC (2016–Present): Compact transverse AWD transfer unit — increasingly available as 2016–2019 units enter the higher-mileage salvage market GLE 350 / GLE 450 4MATIC: Longitudinal transfer case with 45/55 default front/rear split; variable distribution capability; OEM used units from low-mileage US-market donors are the best sourcing option C-Class / E-Class 4MATIC: Compact transfer case units with strong used availability due to high C-Class and E-Class sales volumes G-Class (G550 / G63 AMG): Three-differential AWD with dedicated transfer case and two locking differentials; used units command significant premiums due to low supply and extreme replacement cost new  
      🇩🇪 Quattro & 4Motion Audi Quattro / VW 4Motion
      Audi Q5 / A4 / A6 Quattro / VW Tiguan / Atlas 4Motion — Transfer Case
      Typical Used Price: $380–$880 Audi's Quattro and Volkswagen's 4Motion systems share Torsen-based and Haldex-based transfer case designs depending on the specific model and generation. Longitudinal Quattro (Audi A4, A6, Q5 on the MLB platform) uses a Torsen centre differential — the most mechanically elegant and least failure-prone AWD transfer system in this guide. Transverse Quattro (Audi TT, A3) and VW 4Motion use a Haldex electronically controlled coupling — a different design with its own service requirements.
      Audi Q5 / A4 / A6 Quattro (MLB platform, 2017+): Torsen centre differential transfer case — virtually failure-proof when fluid is maintained; used units are a premium find due to low failure rate Audi Q5 (B8, 2009–2017): Haldex Gen 4/5 rear differential coupling — the most commonly replaced Quattro component; used units widely available from the large B8 Q5 fleet VW Tiguan 4Motion (2009–2017): Haldex coupling — same sourcing considerations as the B8 Q5; cross-reference with Audi Q3 and Skoda Yeti for expanded availability VW Atlas 4Motion (2018–Present): Larger Haldex-based unit for the full-size Atlas; increasingly available as early units enter the used market  
       
      AWD Transfer Case Quick Reference Guide
      Make / Platform Transfer Case Type Used Price Range Availability OEM Critical? Toyota RAV4 / Highlander Electronic ATC / ATC4 $280–$580 ⭐⭐⭐⭐⭐ Yes Subaru Outback / WRX Viscous / DCCD Centre Diff $240–$580 ⭐⭐⭐⭐⭐ Yes Honda CR-V / Pilot AWD RDU / i-VTM4 $220–$520 ⭐⭐⭐⭐⭐ Yes Acura MDX / RDX SH-AWD SH-AWD Torque Vectoring $380–$560 ⭐⭐⭐⭐ Critical Ford Escape / Edge / Explorer PTU (Power Transfer Unit) $260–$680 ⭐⭐⭐⭐⭐ Yes Chevy Equinox / Traverse BorgWarner Electronic $300–$680 ⭐⭐⭐⭐⭐ Yes BMW X3 / X5 xDrive ATC / ATC700 $420–$950 ⭐⭐⭐⭐ Critical Mercedes GLE / GLC 4MATIC 4MATIC Transfer Unit $480–$1,100 ⭐⭐⭐⭐ Critical Audi Q5 / A4 Quattro Torsen / Haldex $380–$880 ⭐⭐⭐⭐ Critical VW Tiguan / Atlas 4Motion Haldex Coupling $320–$680 ⭐⭐⭐⭐ Yes  
       
       
      OEM Used vs. Remanufactured vs. Aftermarket
      🏭 Remanufactured / Aftermarket
      Reman cost: $600–$1,800 — plus core charge of $200–$500 Quality entirely dependent on rebuilder — no OEM quality assurance Electronic components (solenoids, sensors) often reused from worn cores Calibration to vehicle's ECU not guaranteed — fault codes common post-install Core charge adds upfront cost and return shipping hassle New manufacturing environmental footprint on all replacement components  
      ♻️ OEM Used — GreenGears Auto
      Used OEM cost: $220–$1,100 — no core charge Original factory assembly — no rebuilt internals or reused worn components Factory electronic calibration intact — correct OEM integration Mileage-verified from documented low-mileage donor vehicle Free shipping in 3–7 days across the continental US 280 lbs CO₂ prevented per unit vs. new manufacturing  
       
      What to Inspect Before Buying a Used AWD Transfer Case
      Verify Donor Mileage and Service History
      AWD transfer case life is directly tied to fluid maintenance. A 60,000-mile unit from a vehicle with regular fluid changes will outlast an 80,000-mile unit from a vehicle with no documented service history. Always request documented donor mileage — GreenGears Auto records and verifies this on every listing. Drain and Inspect Fluid Condition
      Healthy AWD transfer case fluid is amber or light brown and free of metallic particles. Dark, burnt fluid indicates thermal overload or extended neglect. Milky or foamy fluid indicates water contamination — a serious finding that should disqualify the unit. Metal flakes in the fluid indicate internal gear or bearing wear that may be progressive. Inspect All Seals and Mating Surfaces
      Check the input shaft seal, both output shaft seals, and the housing mating surface for active weeping or dried residue. For Ford PTU units, seal condition is especially critical — seal failure is the most common PTU failure mode and a used unit with compromised seals will repeat the same failure quickly. Verify Electronic Component Integrity
      For electronically controlled AWD transfer cases (BMW ATC, Mercedes 4MATIC, Honda i-VTM4, Ford PTU), inspect the solenoid connectors, wiring harness stub, and any integrated sensors for physical damage, corrosion, and broken pins. A mechanically sound transfer case with damaged electronics will not function correctly after installation. Confirm Exact Application by VIN
      AWD transfer cases vary by engine, transmission, model year, and trim level within the same nameplate. A 2016 Honda Pilot with a 9-speed transmission uses a different transfer case than a 2015 Pilot with a 6-speed. Always cross-reference via the donor vehicle's VIN — part number matching alone is not sufficient for electronically controlled units where software calibration may differ. Check Housing for Cracks and Impact Damage
      Inspect the complete external surface of the housing — particularly the bottom and sides, which are most exposed to road debris. Cracks in the housing are disqualifying regardless of how minor they appear. A cracked housing cannot be reliably sealed and will leak under operating temperature and pressure.  
      ✅ GreenGears Auto's AWD Transfer Case Promise Every AWD transfer case in our inventory is inspected across all six points above before listing. Fluid condition, seal integrity, electronic component status, and donor mileage are documented on every unit. Each is backed by our 90-day satisfaction guarantee with free US shipping and no core charge.    
      Installation Best Practices for AWD Transfer Cases
      Always replace all input and output shaft seals at installation — seal kits cost $30–$90 and prevent the most common post-install failure mode across all AWD platforms Fill with the manufacturer-specified transfer case fluid — using the wrong fluid in an electronically controlled AWD unit causes clutch pack wear, shudder, and premature failure; never substitute generic ATF On BMW xDrive units, code the replacement ATC to the vehicle using ISTA+ before returning to the owner — uncoded units run in a limited default mode On Ford PTU units, inspect and replace the vent tube and breather at installation — a blocked PTU vent causes internal pressure buildup that destroys the output seals Clear all AWD, ABS, and stability control fault codes after installation and perform a calibration drive before finalising the repair On Subaru AWD vehicles, verify all four tires are matched in diameter within the specified tolerance before returning the vehicle — mismatched tires will damage the replacement unit For Mercedes 4MATIC and Audi Quattro applications, verify driveshaft balance and U-joint condition before installation — drivetrain vibration is frequently misdiagnosed as transfer case noise after a swap Road test comprehensively in AWD conditions — wet pavement or gravel is ideal — before completing the repair to verify correct AWD engagement and absence of noise or vibration  
       
      Need an OEM Transfer Case for Your AWD Vehicle?
      Tell us your year, make, model, engine, and transmission — our AWD drivetrain specialists will locate the right inspected OEM unit and get it to you in 3–7 days with free shipping and no core charge.
      GreenGears Auto — Drive Green. Drive Smart.
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    • By NAPA
      NHRA Rookie of the Year contender Maddi Gordon made her presence known Sunday at the NHRA Gatornationals when she raced to a semifinal finish at Gainesville Raceway. Gordon piloted her
      link hidden, please login to view Top Fuel dragster out of the Ron Capps Motorsports camp to round wins over two of the most accomplished drivers in class history before tire smoke ended her run at the opening race of the 2026 NHRA Mission Foods Drag Racing Series season. She leaves Gainesville ranked fourth in the points standings.
      Gordon was the first Top Fuel driver to hit the track in Friday qualifying. Just a couple hours after announcing a multi-year major associate partnership with Monster Energy, Gordon posted a 3.861-second pass at 319.29 mph to take the provisional No. 11 position. She stepped up to a 3.793 E.T. at 321.35 mph in the Friday night session and ended the day in the No. 15 spot. On Saturday, Gordon encountered tire smoke on her third qualifying attempt but came back with a consistent 3.797 E.T. at 328.06 mph in the final qualifying session. It was the quickest pass of the round, netting Gordon three bonus points. She solidified the No. 15 slot going into race day and became the 591st driver and the 23rd woman to qualify for an NHRA Top Fuel field.

      In her first-ever Top Fuel competition round, Gordon lined up against No. 2 qualifier and former world champion Shawn Langdon, who was recently named to NHRA’s Top 75 Drivers list. Crew chief Rob Flynn guided Gordon to her quickest pass of the event, a 3.762 E.T. at 334.48 mph, to get past a tire-smoking Langdon. The competition didn’t get any easier for Gordon, as she went on to face the winningest driver in the history of the class, eight-time world champion Tony Schumacher, when Top Fuel returned to the starting line for the quarterfinals. Gordon powered to a 3.783 E.T. at 331.53 mph to defeat Schumacher and his 3.863 E.T. That sent Gordon to the semifinals and earned her a spot in the first Mission #2Fast2Tasty Challenge of the season, which will take place during Saturday qualifying at the NHRA Arizona Nationals.

      The semifinals brought another battle of youth versus experience as Gordon faced her third “Top 75” driver, two-time and reigning world champion Doug Kalitta. Gordon started hazing the tires early and had to lift off the throttle as Kalitta advanced with his quickest pass of the day.

      “That was just a really, really good weekend,” said Gordon, who became the 100th woman to win an NHRA national event when she drove her family’s Top Alcohol Funny Car to victory at the 2024 NHRA Northwest Nationals. “Of course, we all want to win the race, but I couldn’t have asked for much more in my debut. It was so cool to line up against Shawn in the first round. Rob was confident that the car would get down the track. When I heard (Langdon) blow the tires off in the other lane, I seriously spoke out loud, ‘That wasn’t me! We’re still going!’ Seeing that first win light was insane. I actually started to lose my voice after that one. It’s just been an amazing weekend.”
      Gordon’s rookie campaign will continue at the NHRA Arizona Nationals, March 20-22, at Firebird Motorsports Park near Phoenix.
      Start / Finish: No. 15 / def. in semifinals
      Points Standing / Total: 4th / 74 pts. (-53)
      Next Race: March 20-22,  NHRA Arizona Nationals, Chandler, Ariz.
      How to Watch or Listen: FS1, 
      link hidden, please login to view NAPA Racing:
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    • Government UFO Files
    • By Counterman
      Being a part of your local community is one of the most rewarding benefits of operating any business. Our individual operations certainly take up most of our time and attention, family and other obligations occupy another significant portion, but many of us also manage to carve out the time and energy to share a part of ourselves with the people and organizations that make a ZIP code into a genuine community.
      From serving as school or other organizational board members, coaching local youth sports, or being an active member of your church, friends and neighbors might come to know you both personally and professionally, and your business is often a reflection of those values you already hold dear. As a business, we are also often called upon for financial contributions to a variety of charities, benefits and other generally good causes. The larger the business model, the more these requests roll in, and “the asks” are also generally more substantial. 
      For any automotive business, there are also many requests from members of your local grassroots racing community seeking “sponsorship” for their individual racing interests. These come in many forms, from racers looking to obtain a discounted rate on parts purchases to financially supporting their teams over the course of a season, usually in return for some sort of advertising on the car. On the surface, these requests might seem no different than sponsoring a Little League team or donating items for a benefit auction. Look a bit deeper, though, and you may realize that these racing “sponsorships” really need to be more of a “partnership” to make financial sense
      Too often, a “sponsorship opportunity,” as presented, is a one-sided request, with the team simply seeking assistance in pursuing their dream of competing in motorsports. In exchange for your merchandise or funding, you get… a sticker! When asked just what kind of return on investment you can expect from your sponsorship, the answer is very often stunned silence. If the answer is “free advertising,” then we must truly consider the value of
      that advertising. 
      Most of us have an advertising budget, and use a variety of media to get individual messages out in front of potential customers. It is already increasingly difficult to connect with consumers using traditional print, radio and television advertising. Streaming services and satellite radio both allow consumers to avoid advertisements, and newspaper readership has been declining steadily for years. Having your company name on the fender of a car in front of a few hundred people on a Saturday night might seem like a decent investment, but this kind of individual sponsorship is dependent upon several variables. Failures, successes, team or driver reputations, and even the team’s ability to compete regularly can vastly affect the value of your investment. If you choose to pursue business relationships with individual drivers or teams, think carefully about how those relationships will be mutually beneficial to each party.
      Being associated with the racing community is a great way to connect with your existing clientele, and to keep your name in front of those who might use your services in the future. To maximize your advertising efforts, consider spreading the wealth in a more effective way than through a series of smaller individual sponsorships.
      Advertising at the track itself is a great way to participate without relying on being associated with the most popular or successful team. A trackside billboard is a literal sign of your support for the racing scene, visible no matter which cars are on-track during the various practices, heat races and features. Sponsoring a particular racing class, offering a contingency payment in return for displaying your decals, or even holding a special event on track night, all benefit more than just a few individuals, and partnerships like these also build relationships with the local track operators and their extended network of supporters. 
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