Transfer Case Leak

[G X B]

Has anyone else encountered leaking transfer case on a 5th gen? Odo just rolled past 36,000 miles, Toyota service said not to worry this falls under the powertrain warranty. I will have to schedule another visit for one of their master techs to rip it apart and take photos. As far I can tell the leak does not originate by the shaft seals.

 

[03_4x4Runner]

I hope it does not turn out to be a problem like the 4th gens had. http://www.toyota-4runner.org/4th-gen-t4rs/80283-2004-v8-4x4-actuator-replacement.html My 4th gen had the actuator leak and is one of the reasons I traded it in on my 2014. I hope they made some changes but the transfer case and actuator pretty much look the same.

 

[kry226]

I hope it does not turn out to be a problem like the 4th gens had. http://www.toyota-4runner.org/4th-gen-t4rs/80283-2004-v8-4x4-actuator-replacement.html My 4th gen had the actuator leak and is one of the reasons I traded it in on my 2014. I hope they made some changes but the transfer case and actuator pretty much look the same.

I had that leak too in my 04. It was totally easier and cheaper to replace the entire transfer case than to do what was call for in replacing the actuator seal(s). My leak was at about 150K+ though.

 

[E-ROCKER]

Has anyone else encountered leaking transfer case on a 5th gen? Odo just rolled past 36,000 miles, Toyota service said not to worry this falls under the powertrain warranty. I will have to schedule another visit for one of their master techs to rip it apart and take photos. As far I can tell the leak does not originate by the shaft seals.

I noticed the same leak on my T-case a few months ago. I am at 53,000 miles.
I have never seen it drip so I just call it a little saturation and consider it not enough to be an issue.
Although it seemed a little disappointing for such a new vehicle to have this occurring.

 

[flyinhawyan]

Any updates on this issue? I have a similar leak in the same area.

 

[Friggin Idiot]

I had a transfer case leak in a similar spot with about 20k mi on the odometer. Toyota gave me a Corolla loaner and kept mine for a week while they waited on the parts to come in and get the work completed. All covered under warranty, no related issues since.

 

[G X B]

Any updates on this issue? I have a similar leak in the same area.

After two visits Toyota replaced the whole transfer case. First time they dropped it and changed some seals, few weeks later the oil started leaking again and this time the tech found some casting issue on the tranfer case housing. There were only two new units in the US, I had to wait few days to have one shipped from another state. Toyota (Don Joseph in Kent, Ohio) provided free loaners, it did not matter that I bought my 4runner from another dealership so the overall service experience was fine, they even washed my car before handing back the keys. Interior was a bit dusty though, I tried not to overthink why. Photo shows the new transfer case right after install.

 

[flyinhawyan]

Thanks for the update! I will see what my dealer says tomorrow.

 

[flyboysgt]

Mine had the same thing. Toyota “fixed” it under warranty. Took it for a trip from Kansas to Va... only made it to Missouri. When I got out to get gas, smelled burning oil all over. Looked and it was pouring out. Spent 2 days there (weekend) waiting for the local dealership to open. They again “fixed” the problem after we got a rental to finish our trip to Va. picked up the 4r on the way back. Half way back home same thing. Oil pouring out. Took it immediately to he dealer again when I got home. They had it about a week before they admitted their tech had broken pieces of the transfer case when he reinstalled it. Only problem I’ve had, but man what a nightmare.



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[zerowkul98]

This is scarey-familiar to me too. Both my 4th gens had this issue, cost a pretty penny. Both were around 120-130k on the ODO. Granted, i rarely, if ever, engaged the 4-Lo (both were the V8 4.7's, so it was all-wheel drive), and I know the whole "use it once in a while, or else" scenario, but that was an electric actuator that froze. Now, with the 5th gens, I have the shift knob. Is this actuator problem STILL befalling the 4Runners, even with the lack of the electronic actuator?

 

[the_economist]

I discovered an identical leak on my transfer case today. I'm at 29,000 miles on a 2016 SR5. I'm headed to the dealership tomorrow for (hopefully) a fix under warranty.

I have done only light offroading and have done no mods, so this is a huge black eye on Toyota's supposed reputation for reliability. If I have to have major drivetrain repairs every 30K miles, I might as well just buy a Jeep Wrangler next time around.

UPDATE 1: Toyota dealer didn't really fix. They added dye to the fluid to track the leak, and asked me to return in 500 more miles. We'll see what happens then I guess -- will update this thread then.

UPDATE 2: Second trip to dealership this weekend. Was still leaking from rear power output of transfer case, very slight leak. They had to order a new seal, and they're going to replace it. Taking them 3 days roughly for the repair. The reps at the dealership were incredulous -- could not believe I didn't wreck this myself somehow, or that I bought it new and already have a leaking tranny. Me too haha!

UPDATE 3: Truck has now been at the dealership (Toyota Marin) for a week. They ordered a new seal, pulled the transfer case apart, and then the new seal was no good for some reason. Tech is supposedly ordering a new seal to be delivered tomorrow, at which point they'll reassemble and be done with it. After reading the stories above about problems with casting on the transfer case itself, I'm not convinced this will actually solve the problem. Dealership says no service bulletin is out on this issue yet, but watch for more in coming months and years. The way the cars are built using highly controlled robotic processes, if there is 5 of these out there, then there are probably 1000 out there waiting to be discovered.

 

[TacoRunn0517]

I discovered an identical leak on my transfer case today. I'm at 29,000 miles on a 2016 SR5. I'm headed to the dealership tomorrow for (hopefully) a fix under warranty.

I have done only light offroading and have done no mods, so this is a huge black eye on Toyota's supposed reputation for reliability. If I have to have major drivetrain repairs every 30K miles, I might as well just buy a Jeep Wrangler next time around.

I think you will be okay haha. If the transfer cases of the 5th Gens were that big of an issue, you'd hear about it on this forum. Something tells me you'd have more to complain about if you went with the JKU. Could be wrong though...

 

[the_economist]

Pulling together a couple related threads:

http://www.toyota-4runner.org/5th-gen-t4rs/182021-transfer-case-leak-1.html

http://www.toyota-4runner.org/probl...2016-trail-leaking-transfer-case-fluid-3.html

http://www.toyota-4runner.org/5th-gen-t4rs/241889-transfer-case-leak.html

 

[SparkerCO]

I was under my 2013 w/54k the other day and noticed a Lil fluid there as well. I kinda brushed it off. It's less severe as some of the pics but still present. I'm gonna take it in to the dealer and see what's said.

 

[Carolina Roscoe]

I had the exact same problem at 30K miles. Took it in for the annual DMV inspection and while it was up on the lift we saw oil everywhere. Toyota fixed it under warranty. Now, I go get my 40K a few days ago and they tell me my steering rack is leaking. The gentleman that I deal with at the dealership got Toyota to cover it under warranty even though it ran out a couple few thousand miles earlier. I know most Dealerships are a tad bent but this dude has always done me right and isn't full of it (so far).

 

[zerowkul98]

Re-read this thread, didnt see if anyone answered the poster that asked if this is a problem with the shift-knob TC, the electronic TC or both?

 

[fattire]

Just had a leak fixed in mine about 3 weeks ago. ‘12 Limited. Leak was on the input seal from the transmission. It started super slow. Had the dealership fix it the second I smelled gear oil outside the vehicle.


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[the_economist]

Re-read this thread, didnt see if anyone answered the poster that asked if this is a problem with the shift-knob TC, the electronic TC or both?

My leak was with the electronic 4x4 knob in the SR5. Leak was the rear output of transfer case, right where the rear drive shaft connects.

 

[19994Runner5spd]

Bought this 2011 and completely missed this leak. Think it's leaking between the transmission and the TC. Anyone have any idea from the pictures?

Any idea what this will cost to fix?

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[BlueRidge77]

Transfer case leak at front seal.

I posted this in another thread, but this may be a better location...

Rather than creating a new thread, I thought I would post here. I’ve read several transfer case leak threads. There are different issues I guess. Some have seals leak and others have the gasket/rtv leak between the two castings. I just noticed the leak recently. I just turned over 40k miles on my 16 TEP.

The dealership confirmed the leak and stated it was the front seal. They ordered the parts and I’ll take it in next week to have the work done. Here is my question. The tech said when the front seal is leaking, transfer case fluid can get into the transmission and he recommended a transmission fluid flush at >$400... I argued that if that happens because of a defective part covered under warranty, that should be covered too. I made no progress with the tech or service writer. I’ll save the bickering for when I return. Is that possible though? I would think there is a corresponding seal on the transmission. In order for the TC fluid to get into tranny, wouldn’t the tranny seal be leaking as well? Thoughts appreciated!

Sorry about the rotation...