Transfer Case Leaking

[DesertDune4x4]

As the title states, my transfer case has been leaking (in multiple locations). I should note that i just purchased this truck with ~ 138k miles on it.

After getting the truck up onto the lift to change all the fluids, i noticed there was a lot of thick grime/goopy build-up covering the bottom of the t-case and nearly all the surrounding areas. I drained the fluid...but as soon as i went to torque down the drain plug, i felt it slip and realized i had a nice crack down the threads. Apparently, the previous owner had over-torqued the drain plug, causing a very tiny crack... and now I had just split that crack open more :ybrick: Needless to say, it leaked when i filled the t-case.

I used some JB Weld and some thread sealant as a temporary fix...and this band-aid fix has lasted nearly a month with not even a drip. But after a 200+ mile drive, i now have fresh fluid all over the t-case again. It seems to be seeping out of the gasket (between the two halves of the case), and seeping out somewhere near the bottom of the case.

This problem has got me bummed out about my new toy. Anyone else have any problems with their transfer case? Just curious if it was a common problem...or am I just one of the lucky ones?

 

[96743runner]

My t-case is a little moist on the bottom. It's a really slow leak, and thankfully it's not leaking enough to drip on the ground. One day when I have more time I'll have a better look down there, but hopefully it doesn't get any worse!

 

[rdgt4r]

owie! i havnt heard of this particular issue being a problem on 3rd gens not that ive read about at least. but i do know that it is an extensive fix to get to our transfer cases to my understanding. But i do wish you the best on getting it all straight.

 

[DesertDune4x4]

Yea, it only really leaks when the transfer case gets warm after a 50+ mile drive...

I already ordered a used t-case off another 97 4runner in a wrecking yard. I'm just going to swap the whole thing on my truck rather than try to work with my JB Weld patched case. Hopefully the install won't be too much of a pain in the ass...We'll see how it turns out. I really want to get to spending my money on a lift instead of repairs...but first things first.

 

[shawnstcyr]

Yea, it only really leaks when the transfer case gets warm after a 50+ mile drive...

I already ordered a used t-case off another 97 4runner in a wrecking yard. I'm just going to swap the whole thing on my truck rather than try to work with my JB Weld patched case. Hopefully the install won't be too much of a pain in the ass...We'll see how it turns out. I really want to get to spending my money on a lift instead of repairs...but first things first.

I changed mine out on someones' garage floor with just a floor jack. You will have to remove the shifter handle and the rear cross member. This will allow the engine to lean backwards on the motor mounts. This will allow you to reach the top bolts, vacuum line, and electrical connections. It only took me an hour. Good luck.

 

[JeremyH]

I'm not certain about the 4 Runner t-cases (I have a 2wd), but I have dealt with quite a few of the New Process t-cases and most of them have aluminum cases. I used to get good deals on t-case parts from Novak Adapters (Novak Jeep Conversions - Home). You might be able to find replacement (or upgrade) parts from Originator of Rock Crawling (since 1994) | Marlin Crawler, Inc.

 

[DesertDune4x4]

I changed mine out on someones' garage floor with just a floor jack. You will have to remove the shifter handle and the rear cross member. This will allow the engine to lean backwards on the motor mounts. This will allow you to reach the top bolts, vacuum line, and electrical connections. It only took me an hour. Good luck.

Thank you! Your info on the install is much appreciated. I'll have a lift, air tools, and also a technician working on it with me... so hopefully it will go smoothly. We're going to be putting it on tomorrow or wednesday.


@JeremyH:

Thanks for the heads up. However, I already located a used transfer case in a Toyota wrecking yard for $150. To my knowledge the wrecked truck only has ~35k miles on it, so I'm hoping the t-case should be in pretty good condition. I'll have to check out Novak, though. I've already been browsing around through Marlin Crawler's page

 

[shawnstcyr]

That is dirt cheap! I paid $300 or $350 for one that had 65000 miles on it. Just be aware: I believe SR5 cases are different from the rest.