Changing Differential & Transfer Case Fluids - Pics Included

Personally I would only replace the plugs if it looks like they've been rounded off. Otherwise just gaskets. I tried doing the fluid before getting a bottle pump, don't do that. Definitely get a bottle pump, haha.
Should I buy the Front/Rear Differential and Transfer Case fluid at dealership?
 
Walk into the Toyota parts department with these part drain/filler/plugs numbers and ask for the three different types of fluids?

And I guess a bottle pump can be bought at auto parts store?

I just picked up all the gaskets and plugs for $59 from the dealer I chose to get the plugs as well since they haven't been removed in a while and will be very rusty. The dealer will not sell you the gear oil since they receive it in bulk you have to go to an auto parts store to get it. My owners manual says 75w-90 for front diff and Transfer. For rear differential it says SAE 90 for temp above 0°F and 80w-90 for below 0°F. I asked the deal what they use and he said 80w-90.
So I went to my local Advanced Auto parts and bought 3 qt of Valvoline 75w-90, 1 gallon of Valvoline 80w-90 and bottle pump for $ 40 with a speed perks $20 coupon. I also bought hex sockets from Harbor freight. So now I am ready to tackle this next week on Monday. One dumb question will penetrating oil damage a rusty differential?
 
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I just picked up all the gaskets and plugs for $59 from the dealer I chose to get the plugs as well since they haven't been removed in a while and will be very rusty. The dealer will not sell you the gear oil since they receive it in bulk you have to go to an auto parts store to get it. My owners manual says 75w-90 for front diff and Transfer. For rear differential it says SAE 90 for temp above 0°F and 80w-90 for below 0°F. I asked the deal what they use and he said 80w-90.
So I went to my local Advanced Auto parts and bought 3 qt of Valvoline 75w-90, 1 gallon of Valvoline 80w-90 and bottle pump for $ 40 with a speed perks $20 coupon. I also bought hex sockets from Harbor freight. So now I am ready to tackle this next week on Monday. One dumb question will penetrating oil damage a rusty differential?
Literally just what I'm about to go do. Do you have a receipt from dealer you can send/scan/fax or post?
 
Literally just what I'm about to go do. Do you have a receipt from dealer you can send/scan/fax or post?
Sure here it is.
 

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Just did the rear diff today. I was surprised how easily the drain and fill bolts came off with a 1/2" breaker bar I was expecting it to be very tight and needed to use penetrating oil given the last time it was open was in about 8 years ago by the dealer. I plan to do the transfer tomorrow and if I have time then the front diff otherwise it will be done on Wednesday.
 
I've considered using the heavier stuff a few times, mostly for the rear diff, but chickened out. For one thing, it would hit mpg noticeably, expecially if used in all 3. I don't think I'd use it in the transfer case but it's tempting to use it front and rear.

More discussion, recently, of some rear diff failures has got me thinking about it again.

@JB.

How often should I replace Differential and Transfer Case Fluids? I cannot find anything on the subject in the maintenance section?
 
I have a 2004 V8 and called my dealer. Here's the part numbers he quoted me for the CRUSH WASHERS for this year/model.

Front Fill Plug, Rear Fill plug and Rear Drain plug all use the same washer:
Part - 12157-10010 @ $1.45 each, x3.

Front Drain Plug:
Part - 90430-24003 @ $1.99 each, x1.

Transfer Case Fill plug and Drain plug:
Part - 90430-A0003 @ $1.81 each, x2.

So for the six washers involved, three styles, comes to just under $10 before tax.

This is what I purchased too for all my gaskets.
 
Are you sure you got all the parts and correct number of gaskets?

I ordered verbatim what you had on your recpeit and it seems not all the gaskets are there. I guess just reuse the "breather plugs", whatever they do lol.

The only things i didn't order from the first post were the breather plugs and engine oil pan gasket and plug. I didn't see the need to purchase breather plugs since they don't need to be removed to replace the diff oil. Plus don't know exactly where they are located.
 
Gave this a shot this morning, I started with the transfer case and it went very smoothly. My only concern was that both plugs were the same and neither had magnets. Anyways I cleaned them off, new gaskets and filled and torqued, easy.
Next I went to the front as it seemed the tightest fit (did not use my jack and stands) and the fill plug loosened up so I went to drain it and the drain bolt will not budge. I pb blasted all six last night but this baby didn't move. I actually busted my wrench trying to get it loose so I re torqued the fill plug and moved to the back.
Now I was using a crappy wrench and it did not budge the rear fill plug either. This wrench also broke and would only sometimes turn (ratchet?). So I angrily gave up and cleaned up and called it a day.

Transfer case oil smelled funny (charred ) but went very smoothly aside from expecting a magnet drain plug with stuff on it.
I'm going to pick up a better socket wrench and/or breaker bar before I give it another shot, any suggestions?
 
Gave this a shot this morning, I started with the transfer case and it went very smoothly. My only concern was that both plugs were the same and neither had magnets. Anyways I cleaned them off, new gaskets and filled and torqued, easy.
Next I went to the front as it seemed the tightest fit (did not use my jack and stands) and the fill plug loosened up so I went to drain it and the drain bolt will not budge. I pb blasted all six last night but this baby didn't move. I actually busted my wrench trying to get it loose so I re torqued the fill plug and moved to the back.
Now I was using a crappy wrench and it did not budge the rear fill plug either. This wrench also broke and would only sometimes turn (ratchet?). So I angrily gave up and cleaned up and called it a day.

Transfer case oil smelled funny (charred ) but went very smoothly aside from expecting a magnet drain plug with stuff on it.
I'm going to pick up a better socket wrench and/or breaker bar before I give it another shot, any suggestions?
I had issues with the front drain plug as well. My breaker bar was too long that it touched the floor and there isn't enough space to have the bar horizontal. You just have to find a strong wrench and push hard since the torque spec is around 40ft-lb. Also make sure the hex socket is in all the way I had to tap it in with the back end of a wrench to make it go in all the way.
 
When filling the rear diff I spilled some gear oil on the outside of the diff. What should I use to clean the spill so I can know that no gear oil is seeping through the drain plug. Thanks
 
When filling the rear diff I spilled some gear oil on the outside of the diff. What should I use to clean the spill so I can know that no gear oil is seeping through the drain plug. Thanks

I hate to be that guy, but a rag? Just wipe it down. You'll know if it's leaking.

That being said, I just did my transfer case and rear this past weekend. Front drain wouldn't budge (front fill was no problem) and I ended up starting to strip it so I'll be ordering a new plug before I give the front another shot.
 
I hate to be that guy, but a rag? Just wipe it down. You'll know if it's leaking.

That being said, I just did my transfer case and rear this past weekend. Front drain wouldn't budge (front fill was no problem) and I ended up starting to strip it so I'll be ordering a new plug before I give the front another shot.

Have you tried KRoil (pen oil)? That stuff works magic. I had an 02 sensor that was seized and almost stripped it. A few hits with that stuff and I was able to get it out.
 
I hate to be that guy, but a rag? Just wipe it down. You'll know if it's leaking.

That being said, I just did my transfer case and rear this past weekend. Front drain wouldn't budge (front fill was no problem) and I ended up starting to strip it so I'll be ordering a new plug before I give the front another shot.

Have you tried KRoil (pen oil)? That stuff works magic. I had an 02 sensor that was seized and almost stripped it. A few hits with that stuff and I was able to get it out.

If the penetrating oil doesn't work, clean that off and hit the case(about an inch around the drain plug) with some heat
 
Have you tried KRoil (pen oil)? That stuff works magic. I had an 02 sensor that was seized and almost stripped it. A few hits with that stuff and I was able to get it out.

If the penetrating oil doesn't work, clean that off and hit the case(about an inch around the drain plug) with some heat

Thanks for the advice, I'll give those a try in a couple weeks. I won't have time to make it to the dealership for a plug until then. I was pretty surprised that it stripped considering how easily the fill plug popped. Not even rusty under there.
 
I gave this a try last week but could only get the transfer case done due to seized plugs. Even though I had to give up I hit it a couple times with more pb blaster and lightly tapped the bolts with a hammer.
This morning I was finally able to give it another go with a new harbor freight ratchet and everything went smoothly! Front and back differential plugs came loose with a lot of force. It looked to be the first time it had been done (60k miles) and the oil was thick and had a grayish tint. Both plugs had full magnets of gunk so it was passed time!
Notes: I did it all with out jacking up the truck at all, and it's stock so while tight at times is definitely doable.
Otherwise I followed all the advice here and want to give a big thank you to op and all who gave their input.
 

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