Transfer Case Output Shaft Leak

[rwh963]

Went to Toyota to have new tires mounted, and they did their typical front to back exam. They said i have a minor leak occurring in the transfer case where the propellor shaft exits. i looked under the truck later, and do see a little fluid moisture.

their estimate was only about $300, so given how much they mark up jobs, i figure it probably can't be too difficult to accomplish.

so, wondering if anyone have done this repair themselves, and any pointers.

thx

 

[crimedog]

Had my transmission flushed at the local shop. Reputable place. I had the same seal with a slight leak. They charged me $100 labor, the price for the Toyota seal (about $20) and fluid ($15).

$300 seams pretty steep.

 

[rwh963]

right, probably half the dealer price at an independent. i'm actually wondering about DIY from anyone.

 

[RonJR]

I've done it on the front tcase output on my '94 - I would expect this to be similar.
The basic steps are:
- purchase proper seal
- unbolt drive shaft from output flange
- unstake nut on output flange, use big socket to remove nut (30mm sounds about right)
- remove output flange; should come off fairly easily
- measure seating depth of old seal and record.
- use seal puller or a couple of screwdrivers to remove old seal.
- Tap in new seal to same depth as old one.
- put a bit of rtv on the shaft splines where the flange slides over it, to keep oil from weeping out along the spline grooves.
- Replace parts in opposite order. Make sure to properly torque and stake the nut on the output flange. Toyota recommends replacing the nut every time, but you can get by using the old one if you stake it good. Also be sure to properly torque the driveshaft bolts, and don't substitute anything for the originals. They are special high strength bolts - get replacements if needed from Toyota.

You may need to drain some tcase oil to keep it from leaking out all over the place when you pull the output flange.

It's about an hour job if you're doing it for the first time. If you do a forum search here or on the yotatech forum you should be able to find step by step instructions with pictures. Here's a link that has a bunch of info.
https://www.yotatech.com/forums/f116/rear-oil-seal-transfer-case-224390/

 

[rwh963]

thx for that write up.