Transfer case leak… What is this plug?

[procomsignathid]

Hey all, I noticed a leak from the transfer case this morning after having recently replaced the parking brake & drained / added new gear oil.

I would figure that it would have come from either the drain or fill plug, or perhaps the speedo bullet (it’s the wrong type for this year), but it’s from this other plug.

Any idea what this is/how best to stop this leak? Thanks!

 

[rkymtnflyfisher]

There's an o ring in there, I'm pretty sure you're gonna have to disassemble the t case to fix that.

I just add more oil occasionally.

 

[rkymtnflyfisher]

Idler gear and shaft, that's what that is per the FSM.

There's a stack of gears that ride on that shaft.

 

[rkymtnflyfisher]

 

[procomsignathid]

Oh man. Dont spose theres enough play on that shaft to get to the o ring, haha. Looks like Ill just keep a bit of cardboard under the truck

I appreciate it, might have undid somethin hard to put back together!

 

[rkymtnflyfisher]

I'd bet a guy could replace that o ring without tearing into the case, but I'd sure be prepared for it to become a major project if one gear drops the wrong way.


Cardboard doesn't sound like a bad idea, that's what I do!

 

[Rock40]

What others have said, it’s the reverse idler shaft. In addition to the idler gear, there are two thrust washers, a shim, 2 bearings and a spacer riding on that shaft. It would be incredibly hard, if not impossible, to pull the shaft and swap the o-ring with the case still assembled in the truck. WAY too much stuff to try and keep aligned.

 

[pardion]

Clean the area around the Idler shaft, and the Idler shaft. Spray carb cleaner, air dry, then apply JB Weld over the gaps. Next time you rebuild the transfer case insert a new O ring.

 

[B y r o n]

Instead of JB Weld I think you may have meant this:

 

[Paul_A]

Don't think of it as a leak, think of it as self rust proofing.

 

[procomsignathid]

Since I already have the differential gasket maker stuff (also permatex for grease) i figure I could try that. wont hurt nothin...

 

[ryanwk628]

Id do the FIPG for the time being, just clean it well first. Also check your breather on the top, pressure in cases as they get warm can push lubricants out past seals.

 

[procomsignathid]

ill need to do some digging on the breathers, i forgot about those. i assume xfer case, transmission and the diffs all have breathers?

 

[ryanwk628]

ill need to do some digging on the breathers, i forgot about those. i assume xfer case, transmission and the diffs all have breathers?

Yes they do. They can get clogged up with debris

 

[Living in the Past]

Idler gear and shaft, that's what that is per the FSM.

There's a stack of gears that ride on that shaft.

It's the washer on the front side that I would be worry about the most. It slips down in the case not sure what damage might be done. For that reason I would not attempt replacing the O ring. Remove the seats loosen the the fuel tank to get the transmission cover off and attempt it while installed might be an option. Won't work on 79 and 80 models. Best on a 73 with a three speed and longer transmission cover.

 

[procomsignathid]

It's the washer on the front side that I would be worry about the most. It slips down in the case not sure what damage might be done. For that reason I would not attempt replacing the O ring. Remove the seats loosen the the fuel tank to get the transmission cover off and attempt it while installed might be an option. Won't work on 79 and 80 models. Best on a 73 with a three speed and longer transmission cover.

At this point I've made peace with that O ring ... I'm going to try FIPG after cleaning the area, and if it leaks, I have cardboard to spare. Just got new fill/drain plugs with the hex head for the transmission and diffs, so that's the new weekend project.

 

[Living in the Past]

At this point I've made peace with that O ring ... I'm going to try FIPG after cleaning the area, and if it leaks, I have cardboard to spare. Just got new fill/drain plugs with the hex head for the transmission and diffs, so that's the new weekend project.

My 04 4Runner has had a leak from the transfer case for a long time. Dealer quoted $2,200 to tear the T case apart and replace the O ring for the actuator on full time 4WD to lock. It is a known problem on V8 4Runner and GX470. This vehicle no longer sees a 1,000 miles a year. Some day the stars will align and I'll try the fix where can twist is certain way and remove then change the O ring without tearing it apart. But for now I just be sure the oil doesn't get low. I've put replaced the plugs on a few Land Cruisers that uses the 10 MM allen wrench. 4Runner still use the stock plug without issue. When replacing plugs always loosen the full first. Don't want to drain the oil only to find out the fill plug head is rounded out. Some of the plugs on split transfer cases have very thin heads.