Transfer case actuator leaking!!

zig

New member
Well, the wife just had the ol' T4r checked out today, and they said that the transfer case actuator is starting to leak! Has anyone had or heard of this problem before? The service guy said that he's had one on order for two months now with no luck, and my wife needs to use the vehicle on a trip in a couple of weeks. They claim that it'll be fine for 6-12 months. Any suggestions? How hard would this thing be to change myself? I'm pretty mechanically inclined, but just don't know what I'm getting into.

Thanks
 
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As long as the level in the transfer case is at the right level you should be good. Post pic of leak so we can see the weak point.
 
Ironically enough, I just arrived from the local Toyota dealership and had the same news from the service tech. A transfer case leak at the actuator. I have a 2003 V8 Sport with 100,000 km. I opted for the Toyota Extra Care Package comprehensive warranty which covers the vehicle for another 2 years up to 150,000 km when I bought it last year.

I got really frustrated when the guy told me that, even if the warranty covered the repair, they still needed to open up the transfer case and do a diagnostic which would not be covered (5 hours @ $80/hr). I am now waiting for a call from the service manager as I just don't get it.

Is this a common problem with the 2003 V8?

Mike
 
Monsoon1126 said:
II got really frustrated when the guy told me that, even if the warranty covered the repair, they still needed to open up the transfer case and do a diagnostic which would not be covered (5 hours @ $80/hr). I am now waiting for a call from the service manager as I just don't get it.

I can't comment on the actual problem, but what the dealer is telling you is total BS. Your 4R is under warranty, that means the Toyota service dept. fixes it at no charge including all labor... PERIOD! Call Toyota Canada. Make sure they know that the dealer is trying to charge you for warranty work.
 
Another '03 V8 with the actuator leak here. First dealership just thought it was a seal leaking, replaced it twice, but kept leaking. Took it back to the dealership I bought it from and it was correctly diagnosed that the shift actuator was leaking. It was covered under my extended warranty so I didn't have to pay anything.
 
I know of at least a few dealers who will "double dip". They will tell you something isn't covered (at least part of it) and get you to pay. Then they collect from the factory as well.

I went through it last year with a Nissan dealership. I was so disgusted with the handling of it that I actually sold my Pathfinder at a super low price and walked away. I haven't even owned a car in 3 months now. I am hoping Toyota dealers aren't pulling the same stunt, but it seems pretty prevalent.
 
Well....I spoke to the Toyota dealership again today. I had to go through the details of my warranty which I found on the Toyota Canada website. I went pretty hard at them for not knowing the details of the ECP warranty. He explained that the program is administered by another part of Toyota and that he needs to make sure that all is covered. The details of the warranty basically state that everything in the drivetrain is covered including transfer case and its associated seals.

So, here's my position: They know something is wrong with the transfer case because the thing is leaking fluid. This they admit. Then "Houston we have a problem" right? However, they don't know what kind of problem; hence, the diagnostic of 4 hours which isn't covered. BS!!!

He finally told me that he'd call the ECP department in order to see if the warranty covers the diagnostic and would call me back on Monday.

I'll call Toyota Canada myself if I don't get the answer I want from this guy.

I consider myself a very loyal person when it comes to brands (i.e. cars, boats, electronics, beer); however, once I've turned, I don't come back. I've only owned Toyotas since graduating from University in 1994 and currently drive the 4Runner and a Sienna XLE Limited and am considering getting rid of both as a matter of principle.

Mike
 
I don't think you can judge a brand by one of their dealerships (especially a Canadian one at that! JK :p). Every manufacturer is going to have a percentage of bad dealerships, with some higher than others.

Is there another dealership that you can take it to?
 
Yeah....you're probably right. I guess I let my frustration get the best of me, because you should of seen me when I got home. I came fairly close to launching both.

There is another dealership about 45 min. from here. I will wait for a response on Monday from the local guys.

Thanks,

Mike
 
Yeah....you're probably right. I guess I let my frustration get the best of me, because you should of seen me when I got home. I came fairly close to launching both.

There is another dealership about 45 min. from here. I will wait for a response on Monday from the local guys.

Thanks,

Mike

Hey Mike, any updates on this issue? I'm currently running through a similar problem... thx
 
Well....I spoke to the Toyota dealership again today. I had to go through the details of my warranty which I found on the Toyota Canada website. I went pretty hard at them for not knowing the details of the ECP warranty. He explained that the program is administered by another part of Toyota and that he needs to make sure that all is covered. The details of the warranty basically state that everything in the drivetrain is covered including transfer case and its associated seals.

So, here's my position: They know something is wrong with the transfer case because the thing is leaking fluid. This they admit. Then "Houston we have a problem" right? However, they don't know what kind of problem; hence, the diagnostic of 4 hours which isn't covered. BS!!!

He finally told me that he'd call the ECP department in order to see if the warranty covers the diagnostic and would call me back on Monday.

I'll call Toyota Canada myself if I don't get the answer I want from this guy.

I consider myself a very loyal person when it comes to brands (i.e. cars, boats, electronics, beer); however, once I've turned, I don't come back. I've only owned Toyotas since graduating from University in 1994 and currently drive the 4Runner and a Sienna XLE Limited and am considering getting rid of both as a matter of principle.

Mike


off topic, wats ur choice of beer up there?
 
If you are getting no joy, try using Twitter and Tweet @ToyotaCanada they don't like bad news stories floating around and will contact you to help resolve the situation. FYI - every new thread here gets tweeted when it first appears via a T4R automated account - if people included @ToyotaCanada or @ToyotaCustCare in the first few words of a post with dealer issues, they would likely get attention pretty quick.
 
If you are getting no joy, try using Twitter and Tweet @ToyotaCanada they don't like bad news stories floating around and will contact you to help resolve the situation. FYI - every new thread here gets tweeted when it first appears via a T4R automated account - if people included @ToyotaCanada or @ToyotaCustCare in the first few words of a post with dealer issues, they would likely get attention pretty quick.

So I need to start a new thread about this in order to get some attn is what you're saying?
 
I would set up a Twitter account and tweet from there - they will ask you to Direct Message them with details anyway and you need an account to do that
 
2003 transfer case actuator seal leaking

I hope everyone has their answer by now about this actuator leaking. If someone is replacing the actuator, it is to make money. The leak is caused by a 30 cent o-ring. The reason it costs so much to fix is that the transfer case has to taken down, broken apart, and a few little bolts and circlips removed, attention paid to where the shift forks are. Then, the actuator can be slid out, that sealing area meticulously cleaned, new 30 cent o-ring, and I also used RTV lightly coated on the adjoining surfaces. Then, meticulously clean the sealing surfaces of the case, and reseal it with good RTV. A nice continuous bead, but not too much. I use enamel reducer to do the very final clean of my surfaces and that seems to work well for me before applying RTV. Be anal about drawing the surfaces together and using a torque wrench. Finally, (ask me how I know....) do not over grease your driveshaft yokes. It will apply too much thrust load on bearings that were not made for so much thrust. It is just a whole lot of busy work, but from what I see, and what I've read, anyone who goes down the path of getting a whole new actuator is being taken for a very expensive ride. This job is not technical, but you just have to go into it trusting your sound mechanical ability. And have your truck high enough. You can never have it too high, but it makes it a lot more challenging if you are just on plastic ramps like I was.
 
I hope everyone has their answer by now about this actuator leaking. If someone is replacing the actuator, it is to make money. The leak is caused by a 30 cent o-ring. The reason it costs so much to fix is that the transfer case has to taken down, broken apart, and a few little bolts and circlips removed, attention paid to where the shift forks are. Then, the actuator can be slid out, that sealing area meticulously cleaned, new 30 cent o-ring, and I also used RTV lightly coated on the adjoining surfaces. Then, meticulously clean the sealing surfaces of the case, and reseal it with good RTV. A nice continuous bead, but not too much. I use enamel reducer to do the very final clean of my surfaces and that seems to work well for me before applying RTV. Be anal about drawing the surfaces together and using a torque wrench. Finally, (ask me how I know....) do not over grease your driveshaft yokes. It will apply too much thrust load on bearings that were not made for so much thrust. It is just a whole lot of busy work, but from what I see, and what I've read, anyone who goes down the path of getting a whole new actuator is being taken for a very expensive ride. This job is not technical, but you just have to go into it trusting your sound mechanical ability. And have your truck high enough. You can never have it too high, but it makes it a lot more challenging if you are just on plastic ramps like I was.

NiceLongParagraph.
 

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