'87 FJ60 - Transfer case leak

[stoshzack]

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

 

[Output Shaft]

By the looks of it, there are other oil leaks too.

How to replace that seal is on pg. TF-3 & TF-4 in the MANUAL (link)

See pages attached

 

[stoshzack]

Thanks Output Shaft for the response. I see the replacement for the front and rear oil seals in the manual pages you cited, but not 4WD linkage. Of course, I could be completely missing it...it has been one of those days.

 

[Output Shaft]

You are right, I provided the wrong instructions...duh,

See pg TF-14.14

Normally the procedure to replace that seal is to take apart the transfer case and remove the output shaft assembly with the shift fork and shift fork shaft.

Once that's out, replacing the seal is easy.. Just need a screwdriver to pry it out.

Not sure if it can be done while the shift fork shaft is still installed. Maybe... dunno.

 

[Dooner1]

Also, don't try and pound the seal flush on the outside, you need to leave some space for the boot to slide in behind the seal to keep it in place. It will bottom out inside the case.

 

[Slow Left]

Post #92 on in this thread dealt with the issue of that seal popping out...but I'm not sure if he disconnected the arm at the end of the shift fork shaft, slid the dust boot from the shaft and then slid the seal from the shaft in order to install a new seal in the reverse order. If you try this, I would clean up the shift fork shaft good and lube it with gear oil before sliding the new seal over it so that you don't tear the new seal.

https://forum.ih8mud.com/threads/japeth-the-blue-goat-hillbilly-62-expedition-build.612325/page-5

 

[stoshzack]

Many thanks guys - Great posts! Yes, I am going to attempt the replacement without dropping the transfer case (i.e. the seal & boot over the shaft). Will let you know how it goes.

Stoshzack

 

[Dynosoar]

That seal can be replaced without disassembly of the t case.
Dyno

 

[Spike Strip]

It's been a while, but after a rebuild, that seal leaked because it was torn. I was able to replace it with an OEM seal without dissembling. Just be careful sliding it over the shift lever shaft so the lip isn't damaged by the plastic bushing. Grease the seal lip and apply a thin smear of RTV to the outside surface.

 

[stoshzack]

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).

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.

 

[stoshzack]

Correction - above 4WD bracket is actually connected to transmission case, and not transfer case.

 

[Dent]

So does anyone know where I can get the seal at, or the actual part number. I don't want to buy the wrong one...again.

 

[Spike Strip]

90311-22005 - Seal

36318-60020 - Boot

Looks like both are available from your friendly and knowledgeable Toyota parts slinger.

You sure that's the leak? Looks like it's coming for someplace higher up? Is t'case overfilling?

 

[Dent]

Thank you so very much, I've been chasing this for a while.

 

[stoshzack]

Just saw this thread was resurrected. I ended up pulling the transmission/TC and rebuilding the TC. No leaks now & I am using Redline synthetic.

 

[Desert Tortoise]

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.

Thanks for documenting this procedure!

 

[Hojack]

Yesterday I noticed fluid under the 60. I found it coming from the front output seal on the Tcase. I thought it was the split case gasket but following the oil film it showed it came from the front output seal.

I found this parts breakdown. Looks like I should order. Seal Part # 36134A and the stake nut 36104D. @cruiseroutfit @orangefj45

 

[cruiseroutfit]

Yesterday I noticed fluid under the 60. I found it coming from the front output seal on the Tcase. I thought it was the split case gasket but following the oil film it showed it came from the front output seal.
View attachment 3328514
View attachment 3328513
I found this parts breakdown. Looks like I should order. Seal Part # 36134A and the stake nut 36104D. @cruiseroutfit @orangefj45

Part# TC48009 and TCN22005, we stock them by the hundreds

 

[Hsn]

Many thanks guys - Great posts! Yes, I am going to attempt the replacement without dropping the transfer case (i.e. the seal & boot over the shaft). Will let you know how it goes.

Stoshzack

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

 

[stoshzack]

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

Please see post #10 above