Transmission output shaft seal

[Mean Kitty]

In the middle of changing out a leaking transmission output shaft seal. Today I got the transfer case separated from the transmission. Had about a 1/8 cup maybe less of transmission fluid pour out when I removed the transfer case. There was also a visible line of atf running down the inside of the housing at the bottom off the shaft seal.

I am also suspecting that I probably have a gasket leak on the transmission pan, so since I have everything apart I am going to pull the pan and redo the gasket there.

The extension housing that bolts onto the transmission looks like it also has the same sealer as the transmission pan. I am not sure if I have any fluid leaking from there, so was thinking of possibly pulling the extension housing and redoing that area as well. I have no idea what is on the other side of the extension housing. Can I just unbolt it? or will there be gears and other things that might want to fall out? Attaching a couple pics of where I am at in the tear down.

The extension part I have in question on removing is the area that has the transmission mount attached to it.

Thanks!

 

[Mean Kitty]

Pictures

Here are the pictures (I hope)

 

[brillo_76]

I only had to change that seals when I had a transmission out.. I only changed the input and output seals on both the transmission and transfer cases that I couldn't get to that were internal. I sadly, didn't pull of that extension as I didn't have any leaks and mine was only for prevention methods.

I see you have quite a leak. Is the output bearing shaft ok? No movement, probably impossible to to tell as the transfer shaft slides into it. No heavy wear where the seal hits the shaft?

 

[Mean Kitty]

I only had to change that seals when I had a transmission out.. I only changed the input and output seals on both the transmission and transfer cases that I couldn't get to that were internal. I sadly, didn't pull of that extension as I didn't have any leaks and mine was only for prevention methods.

I see you have quite a leak. Is the output bearing shaft ok? No movement, probably impossible to to tell as the transfer shaft slides into it. No heavy wear where the seal hits the shaft?

The output shaft bearing seems to be ok, at least it didn't seem to have any movement from side to side or in and out, still seems to spin pretty good.

The transfercase input shaft does seem to have a little bit of play in it, maybe 1/64th of an inch. The seal on the input shaft isn't leaking at all, but I am going to change it out while I have it apart. And now that you asked me about the shaft, I think I am going to order a new bearing for the input shaft as well for the transfer case. I really hate to have to pull this apart again in a year when it decides it wants to start leaking. You know how that goes.

I think I am going to pull the extension housing off the transmission just to see whats behind there, and reseal it. I will post a picture on this thread when I remove it, in case anyone else is ever curious whats back there.

I was on a long road trip late spring, and my catalytic converter cracked and eventually broke off at one of the flanges, of course I was about 200 miles for any wheres that had a muffler shop, so I am pretty sure the heat blowing under the truck by the transmission cooked the gasket material, as it was really starting to seep around the panel. After I got a new cat installed, I had about 3000 miles left on my trip, and by the time I got home everything was coated in ATF. I wiped things down a couple days ago around the pan, and I can see new seepage coming out, so hoping most of what is on everything was from the pan leaking. But I am going to try and replace everything and clean everything up that may have gotten damaged from the heat. The ATF is still really nice and clean, no burning smell or anything in the fluid. Just a mess, and fortunately nothing is dripping on the ground.

Will post an update when I pop the transmission extension spacer off. Thanks also for the reply, I am glad you mentioned checking the shaft for damage too, I didn't even check it since the seal wasn't leaking, but I think the bearing may need to be replaced on the transfer case input shaft now. I will take a little video tonight and post it, and you guys can maybe let me know if that looks like excessive play.

 

[brillo_76]

The output shaft bearing seems to be ok, at least it didn't seem to have any movement from side to side or in and out, still seems to spin pretty good.

The transfercase input shaft does seem to have a little bit of play in it, maybe 1/64th of an inch. The seal on the input shaft isn't leaking at all, but I am going to change it out while I have it apart. And now that you asked me about the shaft, I think I am going to order a new bearing for the input shaft as well for the transfer case. I really hate to have to pull this apart again in a year when it decides it wants to start leaking. You know how that goes.

I think I am going to pull the extension housing off the transmission just to see whats behind there, and reseal it. I will post a picture on this thread when I remove it, in case anyone else is ever curious whats back there.

I was on a long road trip late spring, and my catalytic converter cracked and eventually broke off at one of the flanges, of course I was about 200 miles for any wheres that had a muffler shop, so I am pretty sure the heat blowing under the truck by the transmission cooked the gasket material, as it was really starting to seep around the panel. After I got a new cat installed, I had about 3000 miles left on my trip, and by the time I got home everything was coated in ATF. I wiped things down a couple days ago around the pan, and I can see new seepage coming out, so hoping most of what is on everything was from the pan leaking. But I am going to try and replace everything and clean everything up that may have gotten damaged from the heat. The ATF is still really nice and clean, no burning smell or anything in the fluid. Just a mess, and fortunately nothing is dripping on the ground.

Will post an update when I pop the transmission extension spacer off. Thanks also for the reply, I am glad you mentioned checking the shaft for damage too, I didn't even check it since the seal wasn't leaking, but I think the bearing may need to be replaced on the transfer case input shaft now. I will take a little video tonight and post it, and you guys can maybe let me know if that looks like excessive play.

If your fingernail drags on where seal hits, then its grooved.. :-(

Mostly slight seep normal but if a shaft seal is spewing oils... I definitely verify the bearings on the shafts are good because they can wipe out the seals as well.

 

[Mean Kitty]

Got everything put back together about a month ago, and just got back from a 3500mile trip. No leaks, everything is working very good now. The extension adapter is pretty much just that, it did have the FIPG on the side facing the transmission, so it does keep some of the ATF in the transmission, but it does also just pulls off (when the FIPG seal is shot), but it basically just slides past the output shaft, and nothing really complicated with removing and reinstalling it. The rubber gasket on top the transmission (half ball shaped piece was also completely decentigrated, so there was gear oil leaking all over from the top). Picked up a replacement from Marlin Crawler which was great since toyota wants to sell you a whole assembly to get just that little part. Anyways so happy everything is back together, and no issues after a nice long road trip with a fair bit of trails in there as well. Thanks everyone for your input and help on this project