Transfer Case Leak - Help Wanted

[BenderRodriguez]

Can any of you tell where this leak may be coming from, or where to look to determine where it is coming from? I checked the transfer case fluid when I found it and was quite low. I've since filled it up and am hoping to tackle the job myself soon.
Thanks!

 

[Heavy_GD]

You need 3-4 cans of Brakleen to clean all that up then look for the source.

Dont forget to make a blow torch to clear the nozzles for maximum effectiveness.

 

[BenderRodriguez]

:doh::doh:

You need 3-4 cans of Brakleen to clean all that up then look for the source.

Dont forget to make a blow torch to clear the nozzles for maximum effectiveness.

You make two excellent points. I emptied most of a can on it tonight and will check after tomorrow's commute.

 

[Rocko9999]

Soak it with engine degreaser, Simple Green full strength, etc. Let it dwell for a few hours. Hose it off. Monitor for leaks.

 

[ArthurKotb]

It probably won't help but I had a very slow leak in my transfer case on my 2004. It dripped on the driveway until I got tired of looking at it. I took it to my trusted (Toyota certified) local mechanic and he said it was not at all low. The problem was an O-Ring that was leaking and was difficult for him to find. He said it was difficult to reach and most of the work was labor to (I think) remove the case so the O-Ring could be replaced. I said to go for it. The cost was $1141 in Sept 2019. Good luck.

 

[CutthroatSlam]

Like others have said, clean then observe where leak is coming from. Looking at the pic, it looks like the leak is from the output shaft housing seal. If that is where the leak is coming from, you may not have to pull the transfer case to replace the seal. You would have to pull the drive shaft and probably that output housing to remove and install the new seal.

If you want to go cheap, you could try a stop leak additive such as AT-205 Seal Reatorer Stop Leak.

I have been there and have done the job myself. It is not hard and you will save yourself $1,200+:

https://www.toyota-4runner.org/5th-...seal-replacement.html?highlight=Transfer+Case

 

[BenderRodriguez]

Looks like its leaking from here. Thoughts?

 

[Rocko9999]

Hard to tell from that angle. Can you post a couple more? One pic further away.

 

[BenderRodriguez]

Does this one help? There is definitely fresh fluid there, and I couldn't find it anywhere else. I'll look again tomorrow morning.

 

[Rocko9999]

Hard to tell from that pic also. If it's not from the input/output shaft seal, the entire transfer case has to be dropped. Not sure you are up for that.

Year and mileage? Might be worth adding Blue Devil stop leak.

 

[CutthroatSlam]

TBH, I've pulled and replaced the transfer case seals on our 2014 and I am disoriented by your pictures. You need to pull back the camera to give a broader picture, then the closer picture.

Based on the exhaust crossover pipe in the picture and location of your circle and finger point, I would conclude that we're looking at the forward driveshaft. However, your circle and finger point are well forward of the output seal on the transfer case and they are on the underbody of the truck, which suggests we are really talking about splattered grease from the spider gears or u-joints.

I will hedge that due to disorientation and need a broader picture with maybe some painters tape marking the spot. If it is on the output shafts, in theory you could replace it while the transfer case is in the vehicle. I think you need to drive it more to narrow it down.

All that said, pulling the transfer case is not a difficult job. Also, your leak is not bad, which would lead me to first try the AT-205 Seal Repair Stop Leak additive I mentioned above. I had a friend just try this on the leaking front different (output seal) in his Chevy and it worked.

 

[BenderRodriguez]

Here's one zoomed out a bit. The area with the fresh fluid is right above the exhaust in this image. You can't see the leak, but you can see the joint where it is coming from - its the vertical line in the center of the pic.

In a rush right now but will check again in a few days and grab additional pics if needed.

 

[Forrest931]

It could be something more sinister but before you worry too much about it replace the crush washer on the drain and fill the plugs to rule out that possibility. Speedy Garage has a great video on this that I'll link below. He should have part numbers and links in the description.

Hope this helps, best of luck.


https://www.youtube.com/watch?v=-EjdsAuc7RQ&ab_channel=Speedy'sGarage

 

[BenderRodriguez]

It could be something more sinister but before you worry too much about it replace the crush washer on the drain and fill the plugs to rule out that possibility. Speedy Garage has a great video on this that I'll link below. He should have part numbers and links in the description.

Hope this helps, best of luck.


https://www.youtube.com/watch?v=-EjdsAuc7RQ&ab_channel=Speedy'sGarage

Yep, I did that. Drained a small amount of fluid out, replaced the crush washers, and filled it back up. There was not much fluid left - glad I caught it when I did.

 

[Forrest931]

Yep, I did that. Drained a small amount of fluid out, replaced the crush washers, and filled it back up. There was not much fluid left - glad I caught it when I did.

That's super unfortunate when I bought my car the seal was leaking and the push button 4WD wasn't working so I opted to replace the Transfer case entirely. I bought a new (used) transfer case off eBay and threw that in, works great now. for what its worth the job was difficult but doable and required no specialty tools other than a friend and a case of beer.

Best of luck

 

[CutthroatSlam]

Here's one zoomed out a bit. The area with the fresh fluid is right above the exhaust in this image. You can't see the leak, but you can see the joint where it is coming from - its the vertical line in the center of the pic.

In a rush right now but will check again in a few days and grab additional pics if needed.

That’s input shaft seal. You’ll have to pull the transfer case to replace it. Also replace output seal on transmission while you’re in there. See my prior post with link to DIY. It’s about 2 hours out and 2 hours in, plus an hour to clean up and replace the seal.

 

[BenderRodriguez]

That’s input shaft seal. You’ll have to pull the transfer case to replace it. Also replace output seal on transmission while you’re in there. See my prior post with link to DIY. It’s about 2 hours out and 2 hours in, plus an hour to clean up and replace the seal.

I've read your DIY several times. Much thanks to you (and everyone else) who has posted these over the years. Ya'll are saving me thousands of dollars. I used to hate working on cars; the 4Runner and this forum has made it almost fun.

Any other tips or tricks? I'm all ears!:ear:

 

[CutthroatSlam]

I've read your DIY several times. Much thanks to you (and everyone else) who has posted these over the years. Ya'll are saving me thousands of dollars. I used to hate working on cars; the 4Runner and this forum has made it almost fun.

Any other tips or tricks? I'm all ears!:ear:

Just go for it. Really not that difficult of a job and once you're done, you'll be pointing to it and saying "I did that."

 

[BenderRodriguez]

Just go for it. Really not that difficult of a job and once you're done, you'll be pointing to it and saying "I did that."

So far so good, but how do you undo the wiring? Man, that is tucked away and hard to get to.

 

[CutthroatSlam]

So far so good, but how do you undo the wiring? Man, that is tucked away and hard to get to.

I don't remember the specifics, but it was not much of an issue for me.