I recently picked up a '04 4.7/V8 4x4 Limited 4Runner, and while chasing down a transfercase fluid leak, I found that someone had overtightened the fill bolt of the transfercase and cracked the cast aluminum (and beat up the mating surface as well). The crack has started to go out from the neck and into the case, and I found the replacement rear case cover part I need (Toyota #36112-35090) which appears to be for 2003-2022 4Runner and Sequoia (so is this transfercase in the 5th gens as well?) but I'm not sure what parts I can reuse. I would weld the old one, but I don't have a TIG, and can't find a local place that would take the time to preheat and weld cast aluminum. I'll hold onto the old cracked cover for working on it later, but need to get this back on the road so a new cover is my best bet.
I was going to drain and disconnect the actuator, rear driveshaft yoke, and pop the old rear case cover off, press the bearing and race and reuse it in to the new rear cover plate, then reinstall with new rear driveshaft seal. I'm not having much luck trying to figure out which new Toyota seal(s) I may need (listed below), and I was hoping those who have rebuild these transfercases could chime in.
90311-41020 - Seal, Type T Oil
90311-41007 - Seal, Type T Oil
90312-23001 - Seal, Type V Oil
Also, is there a recommended sealant to place on the clamshell mating surfaces when putting it back together? Anything else I'm missing? The overall photo is of the case after I cleaned it to see where things were leaking after a drive - the two closeup photos are from before I cleaned things off.
I was going to drain and disconnect the actuator, rear driveshaft yoke, and pop the old rear case cover off, press the bearing and race and reuse it in to the new rear cover plate, then reinstall with new rear driveshaft seal. I'm not having much luck trying to figure out which new Toyota seal(s) I may need (listed below), and I was hoping those who have rebuild these transfercases could chime in.
90311-41020 - Seal, Type T Oil
90311-41007 - Seal, Type T Oil
90312-23001 - Seal, Type V Oil
Also, is there a recommended sealant to place on the clamshell mating surfaces when putting it back together? Anything else I'm missing? The overall photo is of the case after I cleaned it to see where things were leaking after a drive - the two closeup photos are from before I cleaned things off.
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