Leaking Transfer case motor

[mustang67408]

Look at the pics, that is from a 04 4runner. There are bolts holding the shift forks to the shift shafts of the actuator and there are 3 "C" CLIPS on the shafts. You might be able to open up the actuator and do a reverse removal, but there are tons of small parts inside the actuator and NO INSTRUCTIONS on how it is re-assembled.

[2004_4runner_sport]

Wow, thanks for all your help. I really appreciate it.

[asiamood]

I've got an 03 4Runner Limited and just saw the clearish fluid on the garage floor, looked underneath the buggy and it appears to be a slow drip off that black box (actuator motor) that's connected to the transfer case. I'm interested to know what came out of the original poster's issue. Did you do a new actuator motor for the big bucks or were you able to get the seal replaced? Thanks in advance!!

[bmwfizix]

I just noticed my puddle under my 2004 4Runner V8 Sport Auto. Looks like it is the actuator assembly as others have described. What a disappointment! If anyone has attempted to repair this on their own, let me know because I will attempt the replacement myself. I have rebuilt manual transmissions before so I have some experience. I am not looking forward to this!

[asiamood]

Took my 03 to the Indy today and he says there is an O-ring part available, but alot a labor to put it in, bout a $1200 job, 1195 labor, 5 dollar part. Pretty weak design for sure. It ain't leaking that bad right now so I'm gonna watch it and wait. I've seen entire used transfer cases with 30k miles on them on the net for around $500 bucks. Oh what a feeling!

[bmwfizix]

I replaced the o-ring on the actuator and that stopped the leak (at least for now). Very difficult job – requires removing the entire transfer case and splitting it open to release the actuator which is held by two c-clips. The job required about 22-hours in labor working alone, aside from my father helping with the lowering of the transfer case from the vehicle and helping to split the cases. I was able to do this without removing the transmission (as the manual recommends) by simply tilting the entire transmission/transfer unit until I could remove all of the bolts connecting the transfer to the transmission. This only saves a small bit of time, but the transmission looked so heavy that I felt more comfortable leaving on the vehicle. The transfer case work only took about 3 hours, so the bulk of the time is pulling it down and putting it back up.

[4RunnerDave]

Hey bmwfizix, Any chance you took some photos of your transfer case R&R and have a part number for the o-ring you replaced as I haven't read of anyone else who has ever done this? Thanks, Dave