Transfer case leak

wesel123 · 10-20-2007, 09:37 PM

Hey all,

I noticed a leak this afternoon and the back end of my transfer case between the acutal metal housing and the plasitc center lock housing. Any thoughts as to what it could be????

Thanks guys

bulldog · 10-20-2007, 11:33 PM

Might just be a seal that leaks on the transfer case where the solenoid mechanism bolts into.

wesel123 · 10-21-2007, 10:03 AM

That's what it looks like. Is that something I can tackle my self??? Or is it just too much of a mess???

wesel123 · 10-23-2007, 01:02 PM

Holy cow!!!!!!!!! the stealer is quoting me just shy of $2000. it seems as though the original seal around the acuator/solinoid only comes with the solinoid itself. So that $983 for the solinoid and the balance in labor, ofcoarse you have to take the transfer case apart to remove the solinoid.

Obviously thats out of my ball park so they are going to temp fix it with RVT silicon which the tech said will last between 30,000 and 60,000k.

What really sucks it that this o-ring just failed. I didn't hit it damage it in any way. Even the dealer is supprised.

Its a little disconcerning that my bullit proff toyota has this achillies heal. Im mena really $2000.....did I say Holy Cow!!!!

bulldog · 10-23-2007, 01:10 PM

That just doesn't sound right to me. Maybe have a look at the repair manual to see how things come apart. It doesn't look like a massive job on the face of it.

In actual fact Joel bought and repalced his transfer case for less than that. He bought a 2nd hand unit with solenoid assembly included IIRC.

97kurt · 10-23-2007, 01:49 PM

I'm pretty sure Joel got that entire t-case for under $500 but I could be wrong. You could call TAP recycling and see if they will sell you the solenoid, it wont be cheap but it should be far less than $980.

wesel123 · 10-23-2007, 02:23 PM

There are two forks and 3 circlips (plus the three bolts on the outside) in the interior of the transfer case that would require removal, just to pull the solinoid out. The tech was able to pull the solinoid back about 1/2" which allowed him to see a difformation in the o-ring and also allowed him to clean it up and apply the RVT.

Vegas Runner · 10-25-2008, 10:31 PM

I just experienced this same leak. 5 years and 85,000 miles. It was expensive!

bulldog · 10-25-2008, 11:27 PM

Quote:

Originally Posted by Vegas Runner

I just experienced this same leak. 5 years and 85,000 miles. It was expensive!

Man this is not good news. I hate oil leaks, especially if it is lot of effort to fix them.

my034runner · 10-26-2008, 12:37 AM

Brett had to take and completely disassemble Ed's T-case. I took a few pictures of it all apart, I'll see if I can get them up tomorrow or something.

Teotwaki · 10-26-2008, 09:36 AM

Thanks for posting this item up. I am at 72k miles so I'll keep an eye on that seal.

Vegas Runner · 10-26-2008, 10:50 AM

Yes I hope everyone who gets this leak posts up so we can see if this is another achilles heel like the pass side diff bracket. If it is (and I am not just unlucky) then this is a serious negative for the 4th gen 4runner.

bulldog · 10-26-2008, 10:59 AM

Quote:

Originally Posted by my034runner

Brett had to take and completely disassemble Ed's T-case. I took a few pictures of it all apart, I'll see if I can get them up tomorrow or something.

Yeah kinda sucks to spend hours to replace a part worth a few pennies.

97kurt · 10-27-2008, 09:12 AM

Quote:

Originally Posted by my034runner

Brett had to take and completely disassemble Ed's T-case. I took a few pictures of it all apart, I'll see if I can get them up tomorrow or something.

Sweet, post them up cause I am kinda curious on this one. Any idea if its the 4wd engagement solenoid or the hi-low one?

11-10-2008, 01:54 PM

My 2003 4Runner just encountered the same transfer case leak. No one in town was willing to fix it but the dealer. They quoted me $1500. Thank god for the extended warranty.

Roams001 · 11-15-2008, 02:06 PM

I'm taking off the BudBuilts in preparation for the SAS. I think I may have a leak too. I'll snap some pics tomorrow...I just got rained out.

scottd · 10-30-2009, 04:08 PM

I just found this thread. I think I have developed the same leak. Last time I changed my oil, the area around the actuator looked a little wet. This week I noticed a half-dollar size oil spot under the truck, so this afternoon I crawled under to check it out. Oil appears to be leaking where the actuator goes into the case and running down the back of the case and the actuator and dripping off. And I just hit 67,000 miles this week!

I'm tempted to try the fix posted above - unbolt the actuator, pull it out as far as I can & clean and seal w/RTV, but I don't want to make the leak worse. Guess I'll just live with the leak for now and try the cheap fix if it gets worse.

But I am concerned about the actuator getting damaged by the oil leaking on it. Could the oil leak ruin the actuator?

wesel123 - how is the cheap fix holding up??

expat · 11-08-2009, 07:20 PM

Dammmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmn. I got the leak bad time now! Oh crap! No money to fix. Achilles heel for sure.

java230 · 11-08-2009, 07:38 PM

i think rtv is the answer....

expat · 11-14-2009, 11:29 PM

Anyone who used RTV can report if its holding up? A write-up with pictures would be useful.

10-20-2007, 09:37 PM	#1
wesel123 Rookie Join Date: Feb 2006 Posts: 43	Transfer case leak Hey all, I noticed a leak this afternoon and the back end of my transfer case between the acutal metal housing and the plasitc center lock housing. Any thoughts as to what it could be???? Thanks guys __________________ 2004 V8 4Runner Sport 4wd. OME Heavy Front and Med Rears. ARB Bumper, Shrockworks Sliders. And a bunch of little stuff to boot. 1998 5spd 4 Runner. Downey 3in coil-overs, Boral exahust.

10-20-2007, 11:33 PM	#2
bulldog Admin Join Date: May 2005 Location: Walnut Creek, CA Posts: 12,321	Might just be a seal that leaks on the transfer case where the solenoid mechanism bolts into. __________________ andries K9BDG 2019 Low Rider

10-21-2007, 10:03 AM	#3
wesel123 Rookie Join Date: Feb 2006 Posts: 43	That's what it looks like. Is that something I can tackle my self??? Or is it just too much of a mess??? __________________ 2004 V8 4Runner Sport 4wd. OME Heavy Front and Med Rears. ARB Bumper, Shrockworks Sliders. And a bunch of little stuff to boot. 1998 5spd 4 Runner. Downey 3in coil-overs, Boral exahust.

10-23-2007, 01:02 PM	#4
wesel123 Rookie Join Date: Feb 2006 Posts: 43	Holy cow!!!!!!!!! the stealer is quoting me just shy of $2000. it seems as though the original seal around the acuator/solinoid only comes with the solinoid itself. So that $983 for the solinoid and the balance in labor, ofcoarse you have to take the transfer case apart to remove the solinoid. Obviously thats out of my ball park so they are going to temp fix it with RVT silicon which the tech said will last between 30,000 and 60,000k. What really sucks it that this o-ring just failed. I didn't hit it damage it in any way. Even the dealer is supprised. Its a little disconcerning that my bullit proff toyota has this achillies heal. Im mena really $2000.....did I say Holy Cow!!!! __________________ 2004 V8 4Runner Sport 4wd. OME Heavy Front and Med Rears. ARB Bumper, Shrockworks Sliders. And a bunch of little stuff to boot. 1998 5spd 4 Runner. Downey 3in coil-overs, Boral exahust.

10-23-2007, 01:10 PM	#5
bulldog Admin Join Date: May 2005 Location: Walnut Creek, CA Posts: 12,321	That just doesn't sound right to me. Maybe have a look at the repair manual to see how things come apart. It doesn't look like a massive job on the face of it. In actual fact Joel bought and repalced his transfer case for less than that. He bought a 2nd hand unit with solenoid assembly included IIRC. __________________ andries K9BDG 2019 Low Rider

10-23-2007, 01:49 PM	#6
97kurt Administrator Join Date: Oct 2005 Posts: 498	I'm pretty sure Joel got that entire t-case for under $500 but I could be wrong. You could call TAP recycling and see if they will sell you the solenoid, it wont be cheap but it should be far less than $980.

10-23-2007, 02:23 PM	#7
wesel123 Rookie Join Date: Feb 2006 Posts: 43	There are two forks and 3 circlips (plus the three bolts on the outside) in the interior of the transfer case that would require removal, just to pull the solinoid out. The tech was able to pull the solinoid back about 1/2" which allowed him to see a difformation in the o-ring and also allowed him to clean it up and apply the RVT. __________________ 2004 V8 4Runner Sport 4wd. OME Heavy Front and Med Rears. ARB Bumper, Shrockworks Sliders. And a bunch of little stuff to boot. 1998 5spd 4 Runner. Downey 3in coil-overs, Boral exahust.

10-25-2008, 10:31 PM	#8
Vegas Runner Super Moderator Join Date: Jun 2005 Location: Las Vegas Posts: 1,003	I just experienced this same leak. 5 years and 85,000 miles. It was expensive! __________________ 2003 4Runner SR5 V8 Donahoes, OME 895/N142S, Conferr Rack, Hanna Sliders, Cobra 75WX CB, ARB Air, Dual Batts (24v/12v), Shrockworks Bumper, PIAA 510s & 520s, Rear Floodlights, Oil Filter Relo & Fumoto Valve, BumBuilt Skids, ATG620 Laptop & Docking Station, Kenwood D710A w/ APRS, GPS60, MM 12,000lb Hydraulic Winch, Capstan Winch, Power Steering Cooler & Filter, 1/2" RogerBrown Bodylift Ed-KE7MWY

10-26-2008, 12:37 AM	#10
my034runner Toy120 Uber Mod Join Date: Nov 2005 Location: Las Vegas, NV Posts: 6,676	Brett had to take and completely disassemble Ed's T-case. I took a few pictures of it all apart, I'll see if I can get them up tomorrow or something. __________________ NVTTORA Prez..My034runner: DR/ICON coil overs, Icon 2.5 resis in the rear, custom coil springs, AllPro sliders, BudBuilt skids, KurtFab Lower links, AllPro Upper links, WabFab endlinks, Blackout safari rack, FourTreks HiLift mounts, 285/75/16 BFG's Ko's, MagnaFlow exhaust, Optima Blue&Red top, ShrockWorks bumper, MileMarkerE9000 winch, Engel MT-60 fridge, Sirius, Garmin60 Csx, Factory nav etc...

10-26-2008, 09:36 AM	#11
Teotwaki Adventurer Join Date: May 2006 Posts: 2,714	Thanks for posting this item up. I am at 72k miles so I'll keep an eye on that seal. __________________ Jim My Adventure Blog: "Sun To The North" '05 SR5 4WD V6 HQ sliders, OW Suspension, LT265/75/R16C Duratracs, rear diff. breather, ScanGauge II, Garmin 276C, Engel 45 fridge, All-Pro LCAs, TC A-Arm Skids, dual batteries, Downey skid plate, Cyclone pre-filter, ARB Compressor & Rear Locker!! Offroad Trailer Photos http://www.toyota120.com/forum/showthread.php?t=1237

10-26-2008, 10:50 AM	#12
Vegas Runner Super Moderator Join Date: Jun 2005 Location: Las Vegas Posts: 1,003	Yes I hope everyone who gets this leak posts up so we can see if this is another achilles heel like the pass side diff bracket. If it is (and I am not just unlucky) then this is a serious negative for the 4th gen 4runner. __________________ 2003 4Runner SR5 V8 Donahoes, OME 895/N142S, Conferr Rack, Hanna Sliders, Cobra 75WX CB, ARB Air, Dual Batts (24v/12v), Shrockworks Bumper, PIAA 510s & 520s, Rear Floodlights, Oil Filter Relo & Fumoto Valve, BumBuilt Skids, ATG620 Laptop & Docking Station, Kenwood D710A w/ APRS, GPS60, MM 12,000lb Hydraulic Winch, Capstan Winch, Power Steering Cooler & Filter, 1/2" RogerBrown Bodylift Ed-KE7MWY

11-10-2008, 01:54 PM	#15
blackbear Guest Posts: n/a	Transfer Case Leak My 2003 4Runner just encountered the same transfer case leak. No one in town was willing to fix it but the dealer. They quoted me $1500. Thank god for the extended warranty.

11-15-2008, 02:06 PM	#16
Roams001 No IFS Join Date: Feb 2006 Location: NoVA Posts: 547	I'm taking off the BudBuilts in preparation for the SAS. I think I may have a leak too. I'll snap some pics tomorrow...I just got rained out. __________________ Silver 04 SR5 V8 4x4 Money Pit; KJ4ZMS

10-30-2009, 04:08 PM	#17
scottd Rookie Join Date: Feb 2008 Location: Arizona Posts: 35	I just found this thread. I think I have developed the same leak. Last time I changed my oil, the area around the actuator looked a little wet. This week I noticed a half-dollar size oil spot under the truck, so this afternoon I crawled under to check it out. Oil appears to be leaking where the actuator goes into the case and running down the back of the case and the actuator and dripping off. And I just hit 67,000 miles this week! I'm tempted to try the fix posted above - unbolt the actuator, pull it out as far as I can & clean and seal w/RTV, but I don't want to make the leak worse. Guess I'll just live with the leak for now and try the cheap fix if it gets worse. But I am concerned about the actuator getting damaged by the oil leaking on it. Could the oil leak ruin the actuator? wesel123 - how is the cheap fix holding up?? __________________ 2003 4-Runner V8

11-08-2009, 07:20 PM	#18
expat White Boomer (Kangaroo) Join Date: Jun 2005 Location: SoCal Posts: 5,883	Dammmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmn. I got the leak bad time now! Oh crap! No money to fix. Achilles heel for sure. __________________ 04 V8 SE, Completion date July 24: RST Solid axles Swap, Atlas Crawl Case, 40" Cooper STT Pro's on Fuel Anza D116 Beadlocks, 5:38 gear set, ADS Coilovers, 4x4 labs R.Bumper.

11-08-2009, 07:38 PM	#19
java230 Old Timer Join Date: Mar 2009 Location: Seattle, WA Posts: 2,098	i think rtv is the answer....

11-14-2009, 11:29 PM	#20
expat White Boomer (Kangaroo) Join Date: Jun 2005 Location: SoCal Posts: 5,883	Anyone who used RTV can report if its holding up? A write-up with pictures would be useful. __________________ 04 V8 SE, Completion date July 24: RST Solid axles Swap, Atlas Crawl Case, 40" Cooper STT Pro's on Fuel Anza D116 Beadlocks, 5:38 gear set, ADS Coilovers, 4x4 labs R.Bumper.

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