Transfer Case Actuator Leak - Fix OPTIONS & Thoughts

[chickenman9102]

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!

 

[rdruss]

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.

 

[chickenman9102]

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!

 

[elykrunner]

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 I’m 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 don’t get stranded in snow and need to USE the 4x4 to escape…

 

[Derekv]

If your transfer case doesn’t 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 don’t ignore the issue.

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

That isn’t 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

 

[elykrunner]

If your transfer case doesn’t 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 don’t ignore the issue.

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

That isn’t 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. I’m 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..?

 

[Derekv]

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.

Derek V

 

[DougDolde]

Has anyone tried using JB Weld to fix a small leak?

 

[AndroT100]

Hello....

Just found a leak under my 2003 Sport V8 4x4...only 96K miles...

Is this the actuator leak? I have a half-dollar size spot on the driveway from about 2-weeks of siting and leaking.

 

[AndroT100]

Scheduled with the dealer to do the repair. Quote is $1100. Not leaking very much, but with only 97k miles, all else in great shape, it is worth it to keep all in in good working order. I'm going to speak with them about the double O ring idea. FYI...breather tube is also dry and cracked and not attached. I taped it for now but will ask for a new one in addition.

 

[AndroT100]

My 4Runner is at the dealer for the actuator seals repair. As it turns-out, the plastic of the actuator case is deteriorated and that is where the leak is. Edge of the round area that is around the shafts.

Don't know cost as yet for a new actuator or if a repair, actuator component can be had/installed.

Will update....

 

[ali999]

My 4Runner is at the dealer for the actuator seals repair. As it turns-out, the plastic of the actuator case is deteriorated and that is where the leak is. Edge of the round area that is around the shafts.

Don't know cost as yet for a new actuator or if a repair, actuator component can be had/installed.

Will update....

Hey, any update on this? I have the exact same leak from your pics. Literally from the same spots as well. 1k is not bad at all

 

[ArthurKotb]

Hey, any update on this? I have the exact same leak from your pics. Literally from the same spots as well. 1k is not bad at all

Local trustworthy garage replaced the O-ring in my T4R transfer case in 2019 at 106K miles for $1141.

 

[AndroT100]

Hey, any update on this? I have the exact same leak from your pics. Literally from the same spots as well. 1k is not bad at all

I apologize for the long delay in responding!

Had to replace the actuator which requires removal of the transfer case. Dealer did the job and did a great job!

I'll need to look back at the cost, but it was spendy.

 

[Hungryhawk]

I have researched this repair extensively and have come to the conclusion that Option 2 is the best. You might as well just do it right the first time. I too have read gmyatko's procedure, and while it is a little rough and no pictures it still covers everything and tells you things you don't need to do that the FSM and TSB say to do. I'm going to do mine myself in a few months, just adding TC oil every oil change for now. I'm not a mechanic but can do semi-major repairs (timing belt, CV axle) and am a mechanical engineer so I feel confident I can do this if I approach it methodically and slowly.

Good luck with yours. When are you planning to do your repair? I will definitely be interested in your write-up and lessons learned if you do yours before me. This is a widespread issue on the 03-04 V8 4WD models so I think a lot more owners would be willing to do their own repair if there was a good write-up. TSB (Lexus version) is attached in case you don't have it.

Thanks for posting the detail .pdf. It has completely changed my view of the TC having a few gears and shift forks. I shall give it as much attention as engine & tranny from now on.