**So, I wound up finding some good write ups on this job between the time I wrote this and now. Depending on my mechanic's estimate, I might try it myself.**

Like a good boy, I decided it had been too many oil changes since the last time I greased the ol' drive shaft zerks. I loaded up my grease gun, and went to work. It seemed to take a lot of grease this time around, so I figured I have been low.

I've been smelling a little grease burning off after driving for a while, but just figured that was normal. I came out to the parking spot this morning and saw a nice little 5"x5" puddle below where the front drive shaft connects to the transfer case. It appears the seals have gone bad.

What I'm wondering is the following:

1.) How urgent is this fix?

2.) Can a guy, with limited tools and only a carport, undertake this job in an afternoon? I don't have a torque wrench, or an impact wrench. It's probably time I just go buy a torque wrench at least anyway, but is it really possible to pull the 30mm nut off without an impact wrench? How much would an adequate torque wrench set me back?

3.) What's a reasonable cost for a mechanic to charge for this job? The parts are less than $20, but just wondering about the time. I'll bet if I had a lift, an entire garage, and the experience of doing it before it wouldn't take me more than an hour or so.

Thanks!

Their are quite easy. Search on here. Someone did a really nice write up on the out put seal.

Here you go

Replacing Transfer Case Output Shaft Oil Seals, a How-To for DIY'ers

Cool, I think I can manage this. I'll have to buy some tools, but they'll be tools I need anyway! How long do you think it would take a normal person? I'll add a few hours for my "something always goes wrong" self.

Two questions though:
First, the leak seems pretty significant at this point. It started a few days ago, and is leaving pretty significant spots everywhere I park. I definitely don't want my transfer case running dry, but I'm not sure if it's the sort of thing that can't wait another day of city driving. I could do it tonight, but I won't be able to get to a tool store to get the tools until tomorrow after work.

The last time I changed the t-case oil was about 30k ago, so I'm getting really nervous about running dry.

Second, in the DIY writeup they list a "seal puller". Is there a particular kind of seal puller I need? I'll probably just be going to Sears to get the tools I don't have, but I can't get there until tomorrow after work.

Thanks in advance!
Tony

The seal puller pictured in the beginning of the write up is what you should look for.

The transfer case fluid is probably low but who knows by how much..? Up to you how much more you drive it.

Yeah I was going to, I just didn't know if it had a particular name.

I've changed the T-case fluid before, so I could just add more to it tonight. It's my daily driver, and I work today until 6 and tomorrow until 5. The only place open after 6 on a Sunday is Autozone and their torque wrench selection is a little lacking. Not to mention the parts counter at my local dealership won't be open after I get out tonight either.

Fretting a little...

Scratch that, Toyota parts counters aren't even open on Sundays. Looks like I'll be taking the bandaid approach tonight and adding more gear oil to the t case to hold me over for another day. Oye. =<

Yep, seal puller....



Seal Puller

Well, search "seal puller" on Sears.com and then you might understand my confusion. Sheesh. Tough crowd.

Sorry it came across wrong. I was just joking with you. Yeah I know when you search for seal puller different kinds come up so I gotcha!

No worries! I have also discovered that if you search for "Seal Pull" by accident in an image search you find a bunch of Navy SEALs doing pull ups. Go figure. =p

Ok, so now I'm really confused. I just took off the fill bolt on the t-case and oil (quite clean if I might add) started coming out! It's obviously still full, so I'm wondering if it's really leaking then?

Here's a photo of the leak

Did I maybe just put too much grease in my zirks when I lubed them a few days prior and the excess grease is just liquefying?

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Is that a drip on your skid? If so if it's TC fluid I'd say you have a leak. Grease will shoot out all over after a fresh greasing but it won't turn to liquid like TC fluid. If it's still full it must not be leaking all that much so you probably have time to diag further.

Yeah, it's dripping off of the skid. I smelled it and it's definitely gear oil, I was just really confused when I saw how much of it was coming out over the last two days but the TC was still full! I'm not excited about this, but I'm glad I can drive on it for another day without much issue.

Thanks for the help!

Just want to report that I was able to do this myself using the DIY thread! It took a few hours, and I dropped about $100 on some additional tools, but it was well worth it. There's no more leak and I managed to time the whole thing coincidentally with when I should change my t-case oil anyway! Thanks again for all the help!

I posted this pic of my flange over in the DIY thread, but no one has responded. I'm curious if it is damaged enough to chew up my new seal. It's my daily driver, so I had to just put it all back together to get to work today anyway. I'm OK with doing it all over again though, seeing as it's about $5 for the nut and seal, $15 for the gear oil, and then another $100 or so for the flange. Now that I know how to do it, I'm betting it wouldn't take me more than an hour and a half at worst.

Cheers!

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