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Unread 10-20-2007, 09:37 PM   #1
wesel123
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Default 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
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2004 V8 4Runner Sport 4wd. OME Heavy Front and Med Rears. ARB Bumper, Shrockworks Sliders. And a bunch of little stuff to boot.

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Unread 10-20-2007, 11:33 PM   #2
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Might just be a seal that leaks on the transfer case where the solenoid mechanism bolts into.
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Unread 10-21-2007, 10:03 AM   #3
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That's what it looks like. Is that something I can tackle my self??? Or is it just too much of a mess???
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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.
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Unread 10-23-2007, 01:02 PM   #4
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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!!!!
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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.
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Unread 10-23-2007, 01:10 PM   #5
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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.
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Unread 10-23-2007, 01:49 PM   #6
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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.
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Unread 10-23-2007, 02:23 PM   #7
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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.
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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.
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Unread 10-25-2008, 10:31 PM   #8
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I just experienced this same leak. 5 years and 85,000 miles. It was expensive!
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Unread 10-25-2008, 11:27 PM   #9
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Quote:
Originally Posted by Vegas Runner View Post
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.
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Unread 10-26-2008, 12:37 AM   #10
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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.
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Unread 10-26-2008, 09:36 AM   #11
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Thanks for posting this item up. I am at 72k miles so I'll keep an eye on that seal.
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Unread 10-26-2008, 10:50 AM   #12
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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.
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Unread 10-26-2008, 10:59 AM   #13
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Quote:
Originally Posted by my034runner View Post
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.
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Unread 10-27-2008, 09:12 AM   #14
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Quote:
Originally Posted by my034runner View Post
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?
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Unread 11-10-2008, 01:54 PM   #15
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Default 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.
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Unread 11-15-2008, 02:06 PM   #16
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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.
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Unread 10-30-2009, 04:08 PM   #17
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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??
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Unread 11-08-2009, 07:20 PM   #18
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Dammmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmn. I got the leak bad time now! Oh crap! No money to fix. Achilles heel for sure.
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Unread 11-08-2009, 07:38 PM   #19
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i think rtv is the answer....
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Unread 11-14-2009, 11:29 PM   #20
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Anyone who used RTV can report if its holding up? A write-up with pictures would be useful.
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