Slight transfer case leak

[CruiseOrlando]

I found a new leak on my transfer case this week. I doesn't look bad - but the FSM isn't exactly helpful in tracking down where it might be.

I'm just looking for advise as to what parts I might need to replace. I already plan on doing a front axel rebuild soon, and I'll just add this to to the list when I take care of that, as it's only dripping a little bit each day.

 

[kidglove13]

Rear output seal maybe
If so not an easy job you will need to drop the tcase
If it only drips alittle I would just keep and eye on it and drive it
Only fix it if it really needs it

 

[nuclearlemon]

you only drop part of the tcase. it's not bad, but definitely not as simple as the 40-60 series cases.

 

[CruiseOrlando]

I can't really find anything in the FSM telling me how big of a job this is (or isn't)... I don't have an hour estimate ("if you know what you're doing") either.

I can see only dropping the transfer case from the yoke (doesn't seem hard to get the shaft out), but that's where it gets fuzzy for me. I can't see where the next oil seal might be. I see mention of an "oil storage ring" on the transfer case - is that the likely culprit? There's also a seal before that one, which I guess could be the problem as well... but I certainly don't want to guess wrong, so I'd think you'd want to replace as many as were feasible without going to extremes.

If it's a big job I might just ignore it, but I don't particularly want gear oil all over my driveway either.

Actually, now that I read the FSM more, I'm seeing most of this being done with the case still in the truck...

 

[CruiseOrlando]

Ok, more reading, now I think I know what I'm getting myself into.

I'll have to pull the shaft, then the companion flange on the transfer case. Not certain I'll have to drop it at all for that?

Then the fun part - getting the old seal out. I'm seeing that I need two specialty tools from the FSM. One, a "SST 09330−00021" to remove the nut and plate washer on the flange. Then another SST - (is it one? Or a lot?) SST 09950−30010 (09951−03010, 09953−03010, 09954−03010, 09955−03030, 09956−03020), then the oil seal puller (SST 09308−10010).

I think I'll be in for $300 in tools just to get this job done! Has anyone done this before who can comment on the need for these specialty tools vs. DIY?

Thanks in advance.

 

[CruiseOrlando]

Dang... I was looking at the front diff, not the transfer case. Grrrr...

So I guess I have to pull the front extension housing, then I can get to the seal. But the FSM isn't as detailed as I'd wish for this project...

 

[nuclearlemon]

no sst's used. pull the back half of the case, carefully, iirc, there were loose gears to keep track of. think it took a few hours, but at least part of my tcase was clean when i was done

drain, remove these plugs and unbolt tcase keeping track of which bolts go where. some support will be required because you drop the crossmember.

 

[nuclearlemon]

this is what you will see and have

 

[nuclearlemon]

remove coupler and apparently a pile of other stuff judging by my pictures.

 

[nuclearlemon]

said bolts you need to keep track up. replace seal reassemble. cross fingers

 

[CruiseOrlando]

Thank you, that's just what I was looking for. So I guess just the seal and the gasket are the only replacement parts.

 

[nuclearlemon]

Thank you, that's just what I was looking for. So I guess just the seal and the gasket are the only replacement parts.

i didn't use a gasket...jsut permatex. a change for me, cause normally i always use toyota gaskets. this was a arush job. has held fine for years

 

[Devil's Slide Doug]

I did this job a few months ago, I changed the rear bearing while I was in there. The hardest part for me was separating the rear housing (it was glued on pretty well). I also remember grinding down the tips on one of my snap-ring pliers in order to remove (and replace) one of the tricky hard to access snap rings.

 

[Devil's Slide Doug]

I was lucky that my rear seal sprung a leak about a week before my ipor skidplate/crossmember arrived so I only had to mess with that stuff once.

 

[CruiseOrlando]

Yes, I was reading the other thread, Converting HF2AV Transfer Case into Part Time Transfer Case, and Beno mentions doing that exact same thing to his snap ring pliers.

I was really hoping to not have to dig that far down into the transfer case. Dang. Oh well... mileage, offroading and having fun come at a price

 

[scrowley]

Can someone tell me what this connector is in the last pic? My tcase leaks from this connector/plug whatever it is. I need to order the seal at toyota. thanks

said bolts you need to keep track up. replace seal reassemble. cross fingers

 

[Ebag333]

Speedo sensor. Just an O-Ring.

 

[Devil's Slide Doug]

the oring is an easy one to fix

 

[scrowley]

Thanks. I did order the seal. And a quick search showed what it was and how easy it was.

 

[mtlandcruiser]

I found a new leak on my transfer case this week. I doesn't look bad - but the FSM isn't exactly helpful in tracking down where it might be.

I'm just looking for advise as to what parts I might need to replace. I already plan on doing a front axel rebuild soon, and I'll just add this to to the list when I take care of that, as it's only dripping a little bit each day.
View attachment 571702

How did the job go?