2005 4Runner transfer case issues:

[rgcary]

Just wanted to share something with everyone that I've experienced with my 2005 4Runner LTD 4WD and see if anyone else had these issues?

I bought the vehicle as a certified used SUV with only 2000 miles. I think it had been sitting for a while because the rotors were warped and there were impressions on the rotors from the brake pads. That was the first issue, but in driving it home from VA the transmission was wet and was not while at the dealership. So the pan was leaking and replaced under warranty. Now the transfer case is starting to leak and really has been an issue for a while, which I now have 54,000 miles on it. Overall it has been very good SUV and the leaks are minimal and take a while to show. So I've just about had the entire transfer case replaced and found out today there is another leak on the 4wd actuator assembly. Ugh! Luckily they're working with me on this because I have the extended bumper-bumper warranty up to 100,000 miles or 2011.

Has anyone else ever had these kind of issues? My SUV is a clean machine and very well maintained. Mostly hwy and city driving on the east coast. Pulled a trailer a couple of times and a boat, but maybe a total of 10 times since 2000 miles. This really seems odd for all of this happening.

 

[CJ3Flyr]

I am going to :soapbox: Understand I'm not picking on anybody...


Lack of use trashes stuff faster than anybody could possibly imagine. One of the big offenders can be fluids. They pick up contaminents and moisture. The whole 3months OR 3000miles thing most of us has heard from the Quickie Lube place has merit... I am not saying 3 months is right but for engine oil at least annually and maybe as much as every three months depending on use, climate etc.

Everyone has, at some point, used the A/C in September only to have not work in May. Lack of regular heat cycling and moistening of seals destroys them.

IMHO the transmission and the T-case is probably a combo of the 1st two examples I gave. IMHO trans and gear oil should be changed every 18mos-4years regardless of mileage. I know that's quite a range but there's many other variables too.

No doubt it stinks you're having these problems but IMHO fresh fluid and regular excersise can help prevent these types of problems.
:cheers:

 

[eskimochaos]

I am going to :soapbox: Understand I'm not picking on anybody...


Lack of use trashes stuff faster than anybody could possibly imagine. One of the big offenders can be fluids. They pick up contaminents and moisture. The whole 3months OR 3000miles thing most of us has heard from the Quickie Lube place has merit... I am not saying 3 months is right but for engine oil at least annually and maybe as much as every three months depending on use, climate etc.

Everyone has, at some point, used the A/C in September only to have not work in May. Lack of regular heat cycling and moistening of seals destroys them.

IMHO the transmission and the T-case is probably a combo of the 1st two examples I gave. IMHO trans and gear oil should be changed every 18mos-4years regardless of mileage. I know that's quite a range but there's many other variables too.

No doubt it stinks you're having these problems but IMHO fresh fluid and regular excersise can help prevent these types of problems.
:cheers:

I completely agree with you; however, his leaking transfer case is not unheard of. Furthermore, some dumb engineer made it so you cannot replace the gasket/seal of the actuator to the transfer case without replacing the ENTIRE actuator. I know of some people who have gotten away with smearing high temp silicone all around it.

Best of luck b/c its 22 hours of labor just to get the transfer case off the car.

 

[Mabuse]

22 hours! That's probably longer than it takes to build the whole car on the assembly line.

 

[rgcary]

Thanks..

Thanks for the replies! 22 hours?!? Man I feel sorry for them because they just put the entire transfer case back together, drove it for less then 100 miles and the actuator on the 4wd started to leak and it bolts on the inside of transfer case. I think it would have been much more efficient if they replace the entire transfer case the first go around and then this issue would have not happened and they would have saved 22 hours of labor!

I also wrote Toyota Corp about this because now I'm concerned that other things will leak. The bell housing was damp too, even under the small black cap. They think it's because of the transfer case leaking and it's just flowing down that way. We'll see.

Overall it's a great vehicle, but I must say these issues I'm having are rare. Do you think it's because of it sitting for a while? I bought it at 2000 miles from Alexandria Toyota and now I have 54,000. Ever since the 2000 miles it has always been maintained 100%. I wonder how much of a job it is to replace the BH seal if that's leaking?

 

[rgcary]

one more thing.

When I say maintained I have changed the differential fluids at 30,000 including the transfer case fluids to synthetics 75w-90. What do you run in your transfer case? Toyota said synthetics should be just fine because the book calls for 75-90 anyway. Plugs are changed ever 30,000 per manual.

I follow this below for the maint, as well as checking in with Toyota on what they do at certain mileage intervals.

http://smg.toyotapartsandservice.com/guides.php?xv=1&xy=2004&xint_id=7&v=1&y=2005&int_id=6

 

[CJ3Flyr]

On the t-case there is the 'known issue' as eskimochaos mentioned. It sounds like you are probably a victim of that. On the other maint stuff that I was ranting about it sounds like you're doing well.

It is 22 hours:bash: Who came up with that plan???:wtf:



I use a 75w-90 synthetic in axles & t-case and consider that to be a good choice.

:cheers:

 

[rgcary]

Guess what the toyota dealer found out!

They just found out that the breather baffle on the top of the transfer case was installed the wrong way from the factory? Is this possible? This sounds like it was the problem all along causing the fluid to leak.

 

[CJ3Flyr]

Re: Guess what the toyota dealer found out!

They just found out that the breather baffle on the top of the transfer case was installed the wrong way from the factory? Is this possible? This sounds like it was the problem all along causing the fluid to leak.

IMHO it is possible. If the t-case was pressurizing as it warmed that could force it to leak. If the vent works properly it should release internal pressure but not let air/water back in.

Hopefully it's fixed for you.
:cheers: