Transfer Case Leak - Help Wanted

[BenderRodriguez]

:beer:

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

Thanks! I got them loose, I just needed to step away and come back to it. Now everything is disconnected and I'm struggling to get the transfer case out. I think it's because of the shift lever. This is a Trail, so the 4wd is operated by a lever, and I think it's getting in the way of moving the case back far enough to come out. I have to do some more research.

Edit: Yep, the lever has to come off first. Which means the center console had to come out. All in all, it wasn't too bad. I'll try to post some pics and tips when I put it back together tomorrow, but for now, the case is on the workbench, new seals are in, Permatex is setting, and it is beer-thirty. :beer:

 

[BenderRodriguez]

Finished up the job yesterday afternoon. A couple of pointers -
1. 4runners with a manual shift lever, the lever has to come out before the transfer case. Remove the center console, including the armrest. Remove the transmission shift lever (4 bolts). Then you can get to the transfer case shift lever. It's held in by one c-clip. Stuff a clean rag in the opening to prevent debris from falling in.
2. If you use a floor jack to help raise and lower the transfer case, bring it under the truck from the front or the rear, not the side. This will help you guide the case rearward (to remove) and forward (to install). Seems obvious in hindsight.
3. A battery powered impact wrench and ratchet make the job much easier!
4. A 12mm open-end ratcheting box wrench would be a worthwhile purchase for this job, just for the one bolt that has interference from the transmission mount. You'll likely be saving thousands of dollars doing this yourself, might as well buy a few tools with your savings! Something like this - Amazon.com
5. Take the opportunity to lube your driveshafts while they are sitting on the garage floor!

All in all, it wasn't that bad. It probably took me 16-18 hours total, going slowly and with multiple breaks. I am by no means a mechanic, but this was entirely doable. No leaks noticeable after ~20 miles or so, and it shifts into and out of 4wd smoother at 90k than it did at 50k. Thanks to CutthroatSlam for the writeup and everyone else that has contributed.

 

[CutthroatSlam]

Finished up the job yesterday afternoon. A couple of pointers -
1. 4runners with a manual shift lever, the lever has to come out before the transfer case. Remove the center console, including the armrest. Remove the transmission shift lever (4 bolts). Then you can get to the transfer case shift lever. It's held in by one c-clip. Stuff a clean rag in the opening to prevent debris from falling in.
2. If you use a floor jack to help raise and lower the transfer case, bring it under the truck from the front or the rear, not the side. This will help you guide the case rearward (to remove) and forward (to install). Seems obvious in hindsight.
3. A battery powered impact wrench and ratchet make the job much easier!
4. A 12mm open-end ratcheting box wrench would be a worthwhile purchase for this job, just for the one bolt that has interference from the transmission mount. You'll likely be saving thousands of dollars doing this yourself, might as well buy a few tools with your savings! Something like this - Amazon.com

All in all, it wasn't that bad. It probably took me 16-18 hours total, going slowly and with multiple breaks. I am by no means a mechanic, but this was entirely doable. No leaks noticeable after ~20 miles or so, and it shifts into and out of 4wd smoother at 90k than it did at 50k. Thanks to CutthroatSlam for the writeup and everyone else that has contributed.

Thanks for posting your progress and completion on this. It really is not a bad job. I will be revisiting yours and my write-ups as I think that I will be replacing the transmission on the 2014 pretty soon. Will detach the transfer case first then the transmission.