Leaking Transfer case motor

[2004_4runner_sport]

Hi , I have a 2004 Sport 4Runner with a V8 and just sprung a leak at the transfer case. The truck has about 95,000 miles and has been pretty trouble free.

I just had the 90,000 mile service done about a month ago and now I have a leak. The leak is coming from the motor attached to the back end of the transfer case. I am guessing this is a solenoid that changes the transfer case from Hi to low.

Has anyone else had this problem? The dealer says it could cost up to $1,700 to fix, which I think is a scam. Looks like a $5 O ring is probably bad.

Thanks!

[se7enred7]

I just bought my '03 4runner sport V8 from dealer auction yesterday (dealer friend took me there). After purchasing it, I put it in 4lo just to test it, then it never came out of 4lo.

The toyota technician could not get the vehicle out of 4lo, so I left it for diagnosis. It needs a transfer case actuator. $2600 to fix. $1000 for parts and $1600 for labor and tax. I've read several stories about people having severe troubles with either the actuator or seal. The seal is a really stupid design, where the mechanic has to tear open the transfer case.

So all the money i saved by bypassing the dealership and going to auction is now going to the dealership. Hah! They always get ya...

[2004_4runner_sport]

Great, a crappy design. I expect my 22 year old Alfa to leak a little oil, not my four year old Toyota, serviced 100% by the dealer. Doesn't the V8 4runner sport share the same drivetrain as the Sequioa? I wonder if they have the same problem.

[mustang67408]

Originally Posted by 2004_4runner_sport

Hi , I have a 2004 Sport 4Runner with a V8 and just sprung a leak at the transfer case. The truck has about 95,000 miles and has been pretty trouble free.

I just had the 90,000 mile service done about a month ago and now I have a leak. The leak is coming from the motor attached to the back end of the transfer case. I am guessing this is a solenoid that changes the transfer case from Hi to low.

Has anyone else had this problem? The dealer says it could cost up to $1,700 to fix, which I think is a scam. Looks like a $5 O ring is probably bad.

Thanks!

The entire transfer case has to come apart to replace that actuator. Your right it probably is the "O" RING, but you can not buy it seperatley.

[RobXS]

Originally Posted by se7enred7

I just bought my '03 4runner sport V8 from dealer auction yesterday (dealer friend took me there). After purchasing it, I put it in 4lo just to test it, then it never came out of 4lo.

The toyota technician could not get the vehicle out of 4lo, so I left it for diagnosis. It needs a transfer case actuator. $2600 to fix. $1000 for parts and $1600 for labor and tax. I've read several stories about people having severe troubles with either the actuator or seal. The seal is a really stupid design, where the mechanic has to tear open the transfer case.

So all the money i saved by bypassing the dealership and going to auction is now going to the dealership. Hah! They always get ya...

Wow! I haven't put mine in 4lo in a few years. I really don't have a need for it, but after hearing about that I think I will leave it alone. $2600 is a lot to pay just to find out if something works.

[ALLISONWhite]

can be replaced without drainging completely. u will lose some fluid but not all of it.

[2004_4runner_sport]

Well, the 4runner is back. The independent shop said they got the seal from the Toyota dealer and replaced it. He thought that because some of the parts are plastic they may not be dimensionally stable and wasn't sure if the leak was due to a bad seal or warped plastic servo housing.

Thanks for posting those great pictures. It does not look like a difficult job to remove the servo motor. I assume the motor can be R&R'd W/O taking apart the transfer case? I wonder what I got for $330, a bunch of RTV silicone? I'll have to take a look tonight.

But it cost $330. We'll see if the leak is stopped.

[mustang67408]

Originally Posted by 2004_4runner_sport

Well, the 4runner is back. The independent shop said they got the seal from the Toyota dealer and replaced it. He thought that because some of the parts are plastic they may not be dimensionally stable and wasn't sure if the leak was due to a bad seal or warped plastic servo housing.

Thanks for posting those great pictures. It does not look like a difficult job to remove the servo motor. I assume the motor can be R&R'd W/O taking apart the transfer case? I wonder what I got for $330, a bunch of RTV silicone? I'll have to take a look tonight.

But it cost $330. We'll see if the leak is stopped.

I'd like to know which seal.
Does it have a part number on your receipt? Please post it. I'd love to replace just the seal (if it were available)
The part number will help me find it.
The transfer case has to be taken apart, there are 2 bolts holding the shift rods to the shift forks. (see picture)

[2004_4runner_sport]

Well, looks like I have been scammed.

The leak is back. The shop totally set me up. The shop owner said that since the shift motor has a plastic housing he couldn't guarantee the leak wouldn't return after he replaced the "O" ring. But of course he never changed the O ring because he never removed the motor. He said that he would probably have to replace the shift motor, which he said was a very expensive part, if the first fix didn't work. The shift motor housing is plastic but it's a pretty substantial piece and almost feel s like it's metal. I highly doubt the housing is to blame.

What I found when I crawled under the car was a sealant of some kind spread on the joint between the transfer case and the shift motor. He probably discovered that the shift motor cannot be removed without splitting the transfer case, so he faked a fix with some goo spread on the leak. And since he could not tear the whole thing apart for $300, I got the goo.

My guess is he used the wrong transfer case lube when he did the 90,000 mile service, maybe a synthetic, and it caused the seal to leak.

The invoice just mentions O ring and does not a Toyota part number. I also called the Walnut Creek Toyota dealer and he said that they don't sell the O ring separate.

Looks like I have to go to war with the shop now.

[mustang67408]

Man, that sucks. I hate places like that, gives the rest of us a bad name.
I didn't think he replaced anything with a TOYOTA seal.
I passed this info along to my Toy Rep, about needing a replacement "O" ring. I doubt it will go much farther than him, but I tried.
I hope you nail their A$$ to the wall.

[2004_4runner_sport]

So , in order to replace the O ring you have to split the case, correct? I have the V8 automatic version, with the sports suspension.

[mustang67408]

Originally Posted by 2004_4runner_sport

So , in order to replace the O ring you have to split the case, correct? I have the V8 automatic version, with the sports suspension.

Yes, you have to split the case to remove the ACTUATOR.


PM me your VIN, I may have found the "O" RING. I'll give you a part number, if I can locate the correct one.
Some of vehicles show it in the part imager, some vehicle do not.

[2004_4runner_sport]

We have had our 4Runner serviced at the dealer since it was new. Bit when the dealer wanted $2,500 for the 90,000 mile service we decided to get a second price from a local independent shop. The independent shop was about $1,000 less, so we had the independent shop do the service.

The leak started about a month after the 90,000 mile service.

I guess I will bring it to the Dealer and have them take a look, but it sounds expensive since to fix the leak they have to split the transfer case. And since the O ring isn't sold separately they will probably want to sell me a new shift motor.

[mustang67408]

I found an "O" ring for a 04 4runner, but need your VIN to make sure it is correct for yours.
I can give you the part number if you would like it. Certain 4runners show the "O"ring, everything else does not.

[2004_4runner_sport]

So there is no way to replace the O ring without R&Ring the actuator which requires splitting the case, right? Not a $300 job I am guessing.

Before I accuse the independent shop of screwing me I want to confirm that the case has to be split to replace the O ring. I know they did not split the case for $300.

Doug