Leaking transfer case

[Brussell]

A couple of weeks ago I had the fluid changed in the transfer case and everything was good. It has always been wet but I have never had fluid on the garage floor. The other day I was under it greasing all the zerks and as I'm under there I watch the case start to leak. Since then I have lost about a 1/4 of a cup of fluid out of the case. It is dripping off the connection to the drive shaft. I found myself wondering if I caused the leak as I was greasing things. I can't see how they could be connected but I'm not much of a mechanic. Am I looking a real problem here or did I just over do it on the grease?


Thanks!

Brad

 

[Man Jerk]

Transfer case output seal. No big deal.
Buy a manual and repair it.

 

[fergus]

yeah what manjerk said.Get a seal puller tool too.

 

[Brussell]

Thanks guys! Could you be a little more specific though? Any recomendations on a specific manual? And is that the scientific name --seal puller tool?


Thanks!

Brad

 

[KLF]

No, greasing the driveshaft can't cause the leak.

You don't say if it's the front or rear shaft, but it doesn't matter, procedure it pretty much the same.

You'll need a 32mm socket on a decent sized 1/2" ratchet wrench, a torque wrench, a hammer & punch, a tube of RTV sealant, and a 14mm box wrench. Go to the closest Toyota dealer and buy a new seal and a stake nut. You'll also need some gear lube, as when you pull the old flange off all the lube in the transfer is gonna pour out, so you might as well drain it ahead of time.

If it's the front, put the truck in 4WD. Unhook the driveshaft. Try to unstake the "dent" in the big nut on the end of the shaft. Put the big socket on the nut, unscrew it, throw it away. Pull the flange off. Yank the old seal out, throw it away.

Smear some grease on the lips of the new seal and tap it into the case. Smear some RTV sealant inside the splines of the flange, slide it on the shaft. Smear some more sealant on one side of the big washer, put it on, then screw on the new stake nut. Torque it to spec, I think it's 90 ft-lbs. Then use the punch to stake the new nut into the pair of grooves in the end of the shaft. This is very important.

Put the driveshaft back on. Refill the transfer. All done.

 

[dogboy2]

....then screw on the new stake nut. Torque it to spec, I think it's 90 ft-lbs

94 ft.-lbs. to be exact, as per the Toyota Chassis & Body field service manual (if you don't have this one already Brussell, this would be a great place to start). Also good to have the Haynes Manual for cross reference.

-dogboy- '87 FJ60

 

[Brussell]

Thanks guys! hopefully I'll get to it this weekend.

Brad