'87 FJ60 - Transfer case leak

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Hello there, I am wanting to replace the same boot on the transfer case of my fj60. I wanna know if you were able to replace it without having to take the transfer Case down. N how. Thanx

Yes, simply remove the shift linkage (detailed instructions above) so it looks like this:

1708367490348.png


And then slide the new boot on.
 
Thanks to all who posted. I got the new one installed; my old one was toast. Here is a quick install summary for future interest.

1a) Jack up the front end to avoid losing gear oil once seal is removed (I had some pour out even with a 5 or so degree incline).
1) Remove boot to access seal.
2) Pry out seal with a screw driver (it should come out fairly easily).
3) Time to remove 4WD linkage. Remove the nut on the side of the 4WD support bracket that attaches it to transfer case via the 4WD linkage. Remove the bolt on the top of the 4WD support bracket that attaches it to the transfer case (this is tight and hard to access, but I did it with a snub ratchet) and pull bracket down and to the side (removing it from the transfer case). Set bracket, nut, and bolt aside (see pic below).


View attachment 1117948

4) After bracket is removed, pull down and to the side on the 4WD linkage (i.e. it slides down over the bolt which attaches to the nut you removed above). This will disengage the 4WD linkage from the 4WD shaft that enters the transfer case (i.e. the square tab that simply rests in the shaft relief to move it backward and forward). You just need enough clearance to slide the old seal and boot off, and the new one on; so don't remove the entire linkage.
5) Pull the old seal and boot off.
6) Clean the shaft and remove any and all dirt/debris.
7) Lubricate shaft well with gear oil or grease. I used synthetic grease as it will not degrade the rubber seal.
8) Slide on new seal carefully (in the correct direction).
9) Use RTV on the outer surface of seal if desired. Hand press the seal into place in the transfer case being careful that it seats correctly. Now, reverse the old seal and place it on the shaft to butt up against the new one. Use a pipe and a rubber mallet to gently tap the new seal down (I actually used the metal portion of a vacuum cleaner; it fit onto the old seal perfectly). Make sure the seal taps down evenly (it should go down fairly easily). THE SEAL WILL NOT TAP DOWN FLUSH - THERE IS CLEARANCE FOR THE BOOT ON THE OUTSIDE OF THE TRANSFER CASE AND THE SEAL WILL BOTTOM OUT EXPOSING AN APPROXIMATELY 2-3 MM THICK AREA.
10) Remove old seal from shaft and install new boot (in correct direction). The easiest way to install the boot over the seal is to place your index finger and middle finger over the first fold in the boot closest to the transfer case. Move the bottom portion of the boot over the outer perimeter of seal until the entire boot fits around the seal.
11) Install linkage and support bracket in reverse order.
12) Refill transfer case with gear oil appropriately.

Estimated work time (once you know what you are doing): 40 to 80 minutes.
I will give it a try. Thanx
 
Hi All -

I have a transfer case leak coming from the "front drive shift fork shaft" of the transfer case
(what Toyota calls it, see pic below). I am assuming it is just a matter of replacing the oil seal and dust boot. Can anyone quickly walk me through the steps to replace? Owner's manual and Haynes did not provide any guidance.

Thanks,
Stoshzack
View attachment 1116916
Hello there @stoshzack I assume that you already solved this issue. can you lease share with me the part number of that oil seal, and is it the same for the 60 series transfer case
 
Hello there @stoshzack I assume that you already solved this issue. can you lease share with me the part number of that oil seal, and is it the same for the 60 series transfer case
Please see post #13 above for part numbers. Part number is for FJ60, but may fit other models
 
Finally did the job but I’m stuck on the dust boot… for the life of me I cannot get this dust boot to sit around the lip anyone have any tips?!
 

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