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Old 03-26-2018, 09:22 PM #16
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Quote:
Originally Posted by trackjunky View Post
excellent post. looks like i'll be doing this soon. the tcase wasn't leaking when I got the 4runner used with 110k miles. drove it for year then changed the tcase fluid and it started leaking. been leaking for two years now and it's getting worse. so I'm finally going to bite the bullet and fix it.
I don't remember where I saw it, but if you have the all wheel drive V8 transfer case, when you pull the actuator motor out there is a third hole in the case. On the V6 cases/actuators there is a third shaft that goes through that hole. Another forum member pressed/hammered a small freeze plug in that hole. Normally the shafts and shaft seals help block oil from getting past the case and in the small void between the case and actuator, but in the AWD case that hole is wide open and the only thing stopping oil from leaking out is the large o-ring that you take the actuator out to replace. I would have sourced out a freeze plug and installed it but I didn't read about it until after I had done the repair. I would have also used 2 o-rings on the actuator motor but didn't think about it until afterwards. There is plenty of room in the groove for the o-ring for a second one. I just figure it would be cheap insurance, it's harder for oil to leak past 2 well fitting o-rings.

If you look at the first pic on post #5 that 3rd hole I'm talking about using the freeze plug in is just to the left of the shift shafts.

Last edited by neal0124; 03-26-2018 at 09:26 PM.
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Old 03-27-2018, 03:49 PM #17
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Quote:
Originally Posted by BlackWorksInc View Post
What is this twist method? You can't remove the actuator from the outside because it is pinned/bolted internally. The best method is to rebuild it properly and/or replace it.

Attachment 134272
He may have heard that method from someone doing an actuator o-ring on a GX470.
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Old 01-17-2020, 01:18 AM #18
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Reviving an old thread because I'm officially joining the leaking actuator club.

Noticed the garage floor was developing some oil spots. Examined the transfer case, and it's definitely weeping where the actuator seal is located. Instead of spending thousands to get it fixed, I'm giving AT-205 reseal a shot first. I recently flushed all my fluids, so I went ahead and simply removed about 1/2 quart from the TC. Took a fresh 1/2 quart 75W90 and mixed in 2.5 fluid ounces of AT-205 and pumped it in. Then cleaned the area including the actuator housing of any residual oil. It's been two days and no sign of leaking. I will be monitoring this closely and will post back in few days.
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Old 01-29-2020, 01:21 AM #19
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Just wanted to update

It's been about two weeks and no sign of the leak. So AT-205 seems to have worked in my case. Worth a shot for those with the same issue.
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Old 12-07-2020, 05:50 PM #20
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Quote:
Originally Posted by SolRayz View Post
Just wanted to update

It's been about two weeks and no sign of the leak. So AT-205 seems to have worked in my case. Worth a shot for those with the same issue.
Curious whether this AT-205 ended up being a permanent fix or started leaking again? I have a similar leak of one drop a day but am concerned that it could expend other o-rings or sealing materials to make leaks worse elsewhere or cause other rubber material to become disformed. I say that as someone who is not familiar with other rubber parts the TC gear oil touches.
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Old 10-19-2021, 12:59 PM #21
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Wellp... I purchased this 2004 SR5 4WD knowing that it would probably need some work, but with the head gasket job being done prior to purchase I was pretty confident there wasn't anything hiding...

I haven't had a single leak in the 1,500 miles I have driven the truck until this weekend. I went offroading and camping, upon returning I noticed I was leaking a bit of oil in the driveway. I'm not a big car guy, but I've determined that what I'm seeing is a leaking actuator in the transfer case?

1) Since I was using 4WD and switching in and out a handful of times, it seems like it would make sense that this didn't start til I went out and wheeled a bit..

2) Hoping this isn't a $2K fix, but I am not very hopeful.

Anyone out there able to take a look at these photos and let me know how bad you think it is? Going to call my mechanic today, but this forum is always of immense help.

Thanks!
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Transfer Case Actuator Leak - Fix OPTIONS & Thoughts-screen-shot-2021-10-19-9-37-44-am-jpg  Transfer Case Actuator Leak - Fix OPTIONS & Thoughts-screen-shot-2021-10-19-9-58-14-am-jpg 
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Old 10-19-2021, 08:41 PM #22
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Review the previous posts and write up. Then you or your mechanic should have a good idea of what to expect. Do it yourself and your cost is almost zip.
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Old 10-22-2021, 07:03 PM #23
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Quick Q! Sorry if this is obvious.

The mechanic got this on a lift and showed me where the leak is coming from. Looks like the seal between the actuator and the tcase.

Is that the same seal that everyone else is taking apart the tcase to fix?

Just making sure I am looking at the same issue as the one posted. Thanks!
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Old 10-25-2021, 10:32 AM #24
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Quote:
Originally Posted by chickenman9102 View Post
Quick Q! Sorry if this is obvious.

The mechanic got this on a lift and showed me where the leak is coming from. Looks like the seal between the actuator and the tcase.

Is that the same seal that everyone else is taking apart the tcase to fix?

Just making sure I am looking at the same issue as the one posted. Thanks!
Did he give you a quote to fix it?

Sounds like your in a similar situation. I have no place to work on my car atm, as Iím staying in an Airbnb and was researching the problem before taking it in until I see everyone saying its a $2,000 job.

Mine is leaking a lot, if I ignore it for this month would that cause any longer issues? Assuming I donít get stranded in snow and need to USE the 4x4 to escapeÖ
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Old 10-25-2021, 10:49 AM #25
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If your transfer case doesnít have enough gear oil, it will be damaged or destroyed. Moving parts need lubrication.

You could top off the fluid. That would also tell you how bad the leak is. But donít ignore the issue.

For the V8; Transfer Case: 75W-90 (1.5 quarts/1.4 liters).

That isnít a lot. The fill and drain plugs are 24mm.

Mine was leaking. Bought the 3 seals (2 actuator shaft and 1 front drive shaft output (I think)), dropped the transfer case, opened it and replaced the seals. Put it back together and reinstalled. No more leaks. Took about 3 hours.

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Old 10-25-2021, 11:45 AM #26
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Quote:
Originally Posted by Derekv View Post
If your transfer case doesnít have enough gear oil, it will be damaged or destroyed. Moving parts need lubrication.

You could top off the fluid. That would also tell you how bad the leak is. But donít ignore the issue.

For the V8; Transfer Case: 75W-90 (1.5 quarts/1.4 liters).

That isnít a lot. The fill and drain plugs are 24mm.

Mine was leaking. Bought the 3 seals (2 actuator shaft and 1 front drive shaft output (I think)), dropped the transfer case, opened it and replaced the seals. Put it back together and reinstalled. No more leaks. Took about 3 hours.

Derek V
Thanks. This may sound stupid, is the transfer case always in use or only in 4x4? Trying to figure out how I can get by for the next month without destroying anything. Iím parked on a steep street and its wet outside so not ideal to be pretending to mechanic.

I made an appointment to get it checked out later this week and worst case I could have them top off the fluid..?
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Old 10-26-2021, 03:19 PM #27
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Short answer is yes, it is in use all the time. Without lubrication, the transfer case will eventually over heat and fail.

The transmission sends power to the transfer case and the transfer case sends power to the rear wheels and maybe the front wheels depending on if you have the V6 or V8 and what mode you are in.

On the V8 model, it is full time 4 wheel drive. It is transferring power to the front and rear drive shafts all the time. You can also lock the transfer case.

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Old 11-20-2021, 03:41 PM #28
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Has anyone tried using JB Weld to fix a small leak?
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