Hi everyone, I would start it off right on TW by making a pictorial on how to replace the output shaft seal to stop a common leak and TSB issue. Have to say I was surprised there isn't already one!
Symptoms of a leaky Output Shaft Seal:
(Snatched from a TW help request thread)
You will observe a drop of fluid on the underside of the silver housing and, depending upon severity of the leak, a ring of oil on the undercarriage from ATF slinging off the driveshaft.
The example picture exhibits a considerable leak. On mine I had only observed the drop of fluid and can see only a very faint oil ring.
Seal Driver or 1/2" PVC Union
OEM Toyota Seal 90311-40034
Torque Wrench capable of accurately measuring 27Ft/lbs
Nitrile Gloves (Unless you don't mind dirty hands)
Roller (is really nice to have)
How long it will take? 20 minutes with all supplies on hand.
Some people were concerned about spillage of ATF. I parked on level ground and only lost about 1/8-1/4 cup of ATF, which was mainly in the drive shaft tip that receives the splines.
However much you see yourself lose, remember that your fixing a leak here and it may have added up over time. Grab a quart of ATF from your local dealer and check the fluid level after performing this service.
This is my leak that I had noticed and is one of the two areas we will be working on.
We start off by getting all our tools localized and within reach, working under the truck can be a bit tight.
Block both the front wheels and put the vehicle in nuetral so you can manipulate the driveshaft and transmission splines later.
Once under the vehicle orientate the driveshaft so the U joints appear as they do in the picture above.
I started off by loosening the bolts on the center support located at the middle of the drive shaft using my 24mm socket on a breaker bar.
Dont just take them out or the driveshaft could fall on you if it manages to disengage from the tranny
At this time I placed a jack stand underneath the driveshaft as I had no idea what it weighed and preferred to work with safety.
I then removed the two 14mm bolts while supporting the driveshafts weight and allowed it to rest on the jack stand.
Next I lifted the driveshaft, removed the stand out of the way, and then slowly drop the center section while supporting the tranny end and guiding it out and off the transmission spline end. Be aware a bit of fluid will be in it so don't anything directly beneath this area.
This is how much fluid came out of mine.
And this is the housing of the output shaft seal area, it looks pretty grungy so I will clean it out later before reassembly.
Here, I am using the seal puller to work out the old seal. I found it best to gently work 3 areas to evenly pull the seal. If you dont have a puller go buy one for $7, its no worth scratching the tranny area with screwdrivers and whatnot which could lead to future leakage and its a tool you'll use alot.
POP, out it comes. This is when I cleaned the housing area so that during reassembly we dont get any gunk in the tranny or driveshaft
Here's what the old seals backside looked like, you can see its one lip.
And here we have the new OEM seal, it comes pre-greased, which you can see has a double lip.
I dipped my finger in a very small amount of atf fluid and lubed up the sides of the new seal, then I pushed it into place with my thumbs on either side making sure it seated evenly.
I found that using a piece from a 1/2" PVC union worked perfect for a seal driver, deliver precise taps working around the edge of the PVC piece to evenly seat the seal
Here it is seated into the tranny.
Just lift the driveshaft the same way you removed it and try to connect the end to the splines. If it doesn't go on with a little nudging then set it down and rotate the tranny splines a little bit with your hand and try again. Grab your jack stand now (it is within reach right?) and support the drive shaft with it.
Then grab your 14mm socket and wrench and get the bolts about halfway on, you can then remove the jackstand.
As I snugged down the bolts I tried to center the shaft and center support as much as possible before torquing to 27Ft/lbs.
And your done!
Now add a bit off ATF to the tranny and do a overflow test to make sure your topped off.
I hope this helps some people out!