1. Welcome to Tacoma World!

    You are currently viewing as a guest! To get full-access, you need to register for a FREE account.

    As a registered member, you’ll be able to:
    • Participate in all Tacoma discussion topics
    • Communicate privately with other Tacoma owners from around the world
    • Post your own photos in our Members Gallery
    • Access all special features of the site

transfer case leaking

Discussion in '1st Gen. Tacomas (1995-2004)' started by bphillips, Jul 4, 2010.

  1. Jul 4, 2010 at 7:53 AM
    #1
    bphillips

    bphillips [OP] New Member

    Joined:
    Jul 4, 2010
    Member:
    #39778
    Messages:
    4
    Gender:
    Male
    Vehicle:
    2002 Tacoma auto/4x4/4door
    Hey Guys

    I have a 2002 Tacoma / auto/4x4/4door that has a transfer case leak. I see a small amount coming from the front input saft seal, which I will replace. The one that concerns me is the leak that appears to be coming down from the top of the case. I read there is a breather filter up there that could be stopped up or the gasket on the plate were the shifter rod is bolted to the top of the case. I used brake clean to clean and dry the whole case. I drove it around town for a month and watched it every day. ( no Leaks ). I drove it to the beach, 250 miles ( 60-75 mph ) and check it when I got there. The case was wet from the top to the bottom and appeared to be running down the sides dripping off the bottom of the case I will replace the input shaft seal tomorrow and would like to know what to do or look for on the other leak. Any help or advice would be great....... thanks, bobby
     
  2. Jul 4, 2010 at 7:55 AM
    #2
    chris4x4

    chris4x4 With sufficient thrust, pigs fly just fine. Staff Member

    Joined:
    May 8, 2008
    Member:
    #6497
    Messages:
    104,118
    Gender:
    Male
    First Name:
    FlimFlubberJAM
    Tenoe, AZ
    Vehicle:
    2013 Rubicon Unlimited,
    4.10 gears, sliders, and lots of buttons.
    Welcome to TW!

    Remove the breather, and clean it. You may want to replace it, as they are cheap.
     
  3. Jul 4, 2010 at 8:04 AM
    #3
    bphillips

    bphillips [OP] New Member

    Joined:
    Jul 4, 2010
    Member:
    #39778
    Messages:
    4
    Gender:
    Male
    Vehicle:
    2002 Tacoma auto/4x4/4door
    hey chris,
    what does the breather look like and where is it located, does it screw off or mounted to a plate or the case...this is my first toyota and i'm learning as i go...thanks
     
  4. Jul 4, 2010 at 10:12 AM
    #4
    chris4x4

    chris4x4 With sufficient thrust, pigs fly just fine. Staff Member

    Joined:
    May 8, 2008
    Member:
    #6497
    Messages:
    104,118
    Gender:
    Male
    First Name:
    FlimFlubberJAM
    Tenoe, AZ
    Vehicle:
    2013 Rubicon Unlimited,
    4.10 gears, sliders, and lots of buttons.
    The breather hose attaches to the base of the shifter assembly:

    Here

    Follow the hose up to (IIRC), under the hood, and you will see the hose has a "Cap" on it. Thats the breather. Disconnect the hose at the shifter base, and make sure there are no obstructions.
     
  5. Jul 4, 2010 at 2:37 PM
    #5
    shitroc

    shitroc Master of War

    Joined:
    Oct 14, 2009
    Member:
    #24315
    Messages:
    1,411
    Gender:
    Male
    First Name:
    Ant
    New Brunswick, Canada
    Vehicle:
    2002 Tacoma TRD 4X4
    Listed in sig.......
    ^ yah the breather caps are on the wheelwell on the driverside under the hood.
     
  6. Jul 4, 2010 at 4:55 PM
    #6
    rushr

    rushr Well-Known Member

    Joined:
    May 3, 2010
    Member:
    #36467
    Messages:
    48
    Gender:
    Male
    Vehicle:
    04 DC TRD 4X4
    OME 883 Coils, Dakar Leaf Packs/D6XL AAL, Nitrocharger Sport Shocks, ARB Bumper, Warn M8000 w/Synthetic Line, BAMF Sliders, Odyssey Battery, ProComp 7069 15x8, BFG KM2 33x10.5x15, Frame End Cap Mod, Hayden Transmission Cooler
    The breather tube goes from the base of the shifter to the air space between xfer case and transmission and the breather is pressed into this assembly.

    My breather was not functioning causing pressure to build. Oil was leaking around the input seal and shifter boot then running down the side of the xfer case.
     
  7. Jul 4, 2010 at 9:19 PM
    #7
    Digiratus

    Digiratus Adventurer

    Joined:
    Mar 26, 2010
    Member:
    #34006
    Messages:
    10,952
    Gender:
    Male
    First Name:
    Mike
    Roaming the PNW
    Vehicle:
    The RedHead
    2002 XtraCab TRD 4x4 Auto Trans With Lots of Mods King ET Coilovers Camburg Uniball UCAs Alcan 8-Leaf Rear Spring Packs Fox 2.0 Resi Rear Shocks FrankenFab Rear Shock Relocate Trail Gear U-bolt Flip Toytec 1" Extended Shackle 4.88 Nitro Gears ARB Front Locker OBA ARB Twin Comp 15x8 D Window Steelies 33" BFG KM2s Limited Edition Elite Front Bumper Smittybilt X2O 10K Winch PIAA 510 SMR Fog Lights Lightforce 170s Badland Sliders FrankenFab Tire Carrier Swingout bumper w/kitchen BudBuilt Front & Bellypan Skids BAMF Rear Diff Skid Whynter 65 qt. Fridge/Freezer CVT Mt Bachelor RTT Badland Custom Bed Rack GM 140 amp alternator Optima Yellow Top battery Magnaflow 18" Muffler Braided Steel Brake Lines AFE Pro Dry S air filter ScanGauge II OBDII Scanner Uniden 520xl CB radio 3' Firestik Adjustable tip antenna Pioneer DEH-P9400BH HU Alpine Amps & Type R components (F) and coaxials (R) Wet Okole Seat Covers Weathertech Digital Liners Deck Plate Mod 1" Diff Drop Carrier Bearing Drop
  8. Jul 26, 2010 at 6:13 PM
    #8
    hburg2002tacoma

    hburg2002tacoma New Member

    Joined:
    Oct 14, 2009
    Member:
    #24286
    Messages:
    2
    Gender:
    Male
    First Name:
    Don
    Harrisonburg, VA
    I got a leak near the shifter rod. Can I replace this gasket only or do I need to replace all gaskets?
    What is this gasket officially called, I'm not a mechanic, so any help will be greatly appreciated.
     
  9. Oct 21, 2010 at 7:58 AM
    #9
    Kuneff

    Kuneff Carpe Diem

    Joined:
    Nov 19, 2009
    Member:
    #26173
    Messages:
    764
    Gender:
    Male
    West Virginia
    Vehicle:
    Tacoma Woods Beater
    Tree Dents
    Here is my contribution to the leaking Transfer case...

    Mine was getting soaked on both sides... leaking like crazy. I was going to add fluid last night to buy some time till I could tear into it, and realized this was a walk in the park and I could have it fixed in not much more than an hour...


    I made my own gaskets out of fel-pro brand gasket paper. It came from Advance auto if I remember right. Basically you just lay the old gasket on it, trace it then cut it out with scissors or an x-acto knife. If you have a single hole hole punch it makes it a lot easier on the bolt hole area. I could not find mine last night, and didn't wanna lose time looking for it. if yours is leaking then the current gaskets should be so oil soaked they peal right off to use as templates.

    Quick shot of how bad it was leaking...
    [​IMG]

    Access to the top of the shifter area. Carpet was not even in the way. Just make sure when you put the main boot/seal back in that you get it against the metal of the cab floor and not stuck on top the carpet.
    [​IMG]

    The culprit of the leak...
    [​IMG]

    One gasket traced out...
    [​IMG]

    That little metal plate that goes between the shifter and the transfer case has a gasket on each side. So you gotta make or buy 2 gaskets. I prefer to make them. I cleaned off all the residue and grim on the bottom of the shifter, each side of the metal plate and off the top of the transfer case. Wiped it down with some lacquer thinner to get the oil off. I put a very thin layer of Black RTV on both sides of each gasket for a better chance of a good seal.

    There is a breather vent right in front of the opening for the 4x4 shifter, check it and make sure its not gummed up. Also, make sure you hook up that little rubber line from the tranny to the Transfer case shifter.
     
  10. Oct 21, 2010 at 8:39 PM
    #10
    Digiratus

    Digiratus Adventurer

    Joined:
    Mar 26, 2010
    Member:
    #34006
    Messages:
    10,952
    Gender:
    Male
    First Name:
    Mike
    Roaming the PNW
    Vehicle:
    The RedHead
    2002 XtraCab TRD 4x4 Auto Trans With Lots of Mods King ET Coilovers Camburg Uniball UCAs Alcan 8-Leaf Rear Spring Packs Fox 2.0 Resi Rear Shocks FrankenFab Rear Shock Relocate Trail Gear U-bolt Flip Toytec 1" Extended Shackle 4.88 Nitro Gears ARB Front Locker OBA ARB Twin Comp 15x8 D Window Steelies 33" BFG KM2s Limited Edition Elite Front Bumper Smittybilt X2O 10K Winch PIAA 510 SMR Fog Lights Lightforce 170s Badland Sliders FrankenFab Tire Carrier Swingout bumper w/kitchen BudBuilt Front & Bellypan Skids BAMF Rear Diff Skid Whynter 65 qt. Fridge/Freezer CVT Mt Bachelor RTT Badland Custom Bed Rack GM 140 amp alternator Optima Yellow Top battery Magnaflow 18" Muffler Braided Steel Brake Lines AFE Pro Dry S air filter ScanGauge II OBDII Scanner Uniden 520xl CB radio 3' Firestik Adjustable tip antenna Pioneer DEH-P9400BH HU Alpine Amps & Type R components (F) and coaxials (R) Wet Okole Seat Covers Weathertech Digital Liners Deck Plate Mod 1" Diff Drop Carrier Bearing Drop
    ^^^Thanks for the info and pics. Mine is starting to seep a little. I'm thinking I may need to do this soon.
     
  11. Oct 22, 2010 at 5:35 AM
    #11
    Kuneff

    Kuneff Carpe Diem

    Joined:
    Nov 19, 2009
    Member:
    #26173
    Messages:
    764
    Gender:
    Male
    West Virginia
    Vehicle:
    Tacoma Woods Beater
    Tree Dents
    For something that is such a simple fix... I would not wait. the longer you wait, the more fluid you will have built up on the case, rear end and tailgate... I am just glad I could contribute some...

    I am anxious to start the bed bobbing project so I can make a nice write up/pic thread on that... :D
     
  12. Oct 24, 2010 at 7:01 PM
    #12
    Kuneff

    Kuneff Carpe Diem

    Joined:
    Nov 19, 2009
    Member:
    #26173
    Messages:
    764
    Gender:
    Male
    West Virginia
    Vehicle:
    Tacoma Woods Beater
    Tree Dents
    My Transfer case is dry as a bone now... The gaskets fixed the leak....
     
  13. Jun 4, 2012 at 5:40 PM
    #13
    Beau02

    Beau02 Black Taco

    Joined:
    Oct 28, 2009
    Member:
    #25082
    Messages:
    247
    Gender:
    Male
    First Name:
    Beau
    Indianapolis, IN
    Vehicle:
    2002 4x4 Limited TRD V6 Auto (176k, 1-owner)
    Lots of small stuff; Grillcraft MX, Bilstein 5100's, Deck Plate Mod w/ K&N air filter, Airaid MIT, braided SS brake lines, Redline Tuning QuickLIFT hood struts, Extang Full-Tilt tonneau cover, fog light mod, gray wire mod, power outlets on-demand, Diff breather ext, additional contours to passenger side from oak tree.
    I know this subject has been beat to death on the forum, but I've read through all of the threads I can find on the subject and I still have questions about my '02 with A/T.

    This particular thread got the closest to what I need. I've got the same leaking issues as are typical from what I can see and I want to check if the t/c breather is occluded. What's throwing me off is this; I have the two breathers in the engine compartment (which I've been certain all along are the front diff and transfer case), but when I dug into the top of the transfer assembly from inside the truck to locate the hose I found a damn breather cap! See photos below - they show the two breathers under the hood as well as the cap I mentioned.

    They aren't great photos, but the cap is a little forward and to the driver's side of the transfer shifter (the transfer shifter can be seen in the photos).

    My questions are this:

    1. Is the breather in the two photos for the transfer case?
    2. If it is, what is the second breather cap in the engine compartment for?
    3. The single breather shown in the photo doesn't have any flats or obvious ways of removing it. How would it be taken out for inspection?
    Any help would be greatly appreciated!

    Breather1.jpg
    Breather2.jpg
    Breather3.jpg
     
  14. Jun 5, 2012 at 6:15 AM
    #14
    rushr

    rushr Well-Known Member

    Joined:
    May 3, 2010
    Member:
    #36467
    Messages:
    48
    Gender:
    Male
    Vehicle:
    04 DC TRD 4X4
    OME 883 Coils, Dakar Leaf Packs/D6XL AAL, Nitrocharger Sport Shocks, ARB Bumper, Warn M8000 w/Synthetic Line, BAMF Sliders, Odyssey Battery, ProComp 7069 15x8, BFG KM2 33x10.5x15, Frame End Cap Mod, Hayden Transmission Cooler
    Yes

    Front diff and ADD actuator

    It is pressed in . I pulled the cap off mine which leaves a nipple and attached a hose to it
     
  15. Jun 5, 2012 at 6:11 PM
    #15
    Beau02

    Beau02 Black Taco

    Joined:
    Oct 28, 2009
    Member:
    #25082
    Messages:
    247
    Gender:
    Male
    First Name:
    Beau
    Indianapolis, IN
    Vehicle:
    2002 4x4 Limited TRD V6 Auto (176k, 1-owner)
    Lots of small stuff; Grillcraft MX, Bilstein 5100's, Deck Plate Mod w/ K&N air filter, Airaid MIT, braided SS brake lines, Redline Tuning QuickLIFT hood struts, Extang Full-Tilt tonneau cover, fog light mod, gray wire mod, power outlets on-demand, Diff breather ext, additional contours to passenger side from oak tree.
    Thank you for the reply rushr. I had no idea the second breather cap under the hood was for the A.D.D. actuator . . . I've been living a lie!!!
     
  16. Jun 9, 2013 at 5:10 PM
    #16
    Andys Toy

    Andys Toy Member

    Joined:
    Jun 9, 2013
    Member:
    #105916
    Messages:
    19
    Gender:
    Male
    First Name:
    Andy
    So Cal
    Vehicle:
    2002 TRD
    6" lift , 35" tires , winch
    Just joined the site. I bought a 2002 tacoma for my kid today with the same problem. Is the process the same whether its a stick or automatic trans. His is a stick if it matters. By the way good response to the problem with all the pics.
     
  17. Jun 9, 2013 at 10:21 PM
    #17
    License2Ill

    License2Ill Well-Known Member

    Joined:
    May 20, 2012
    Member:
    #79174
    Messages:
    435
    Gender:
    Male
    First Name:
    Ian
    Mendocino County, CA
    Vehicle:
    SC'd 04 TRD 4x4
    Icon Ext Trvl w/ 14"x700#, LR UCA, Yukon 4.88's, front Trutrac, Dakars w/ double D6XL, Nitro LC 60065 rears, Timbren bumpstops, Manual hubs, Demello Sliders, ARB w/ Warn 9.5xp & endcap mod, CBI rear w/ swingout/boxed frame & demello plates. Rear shock relocate, U-bolt flip. 5 speed swap; hopefully soon. :)
    What's the issue? Leaking from the shifter or from the shaft seal?
     
  18. Jun 10, 2013 at 7:03 AM
    #18
    Andys Toy

    Andys Toy Member

    Joined:
    Jun 9, 2013
    Member:
    #105916
    Messages:
    19
    Gender:
    Male
    First Name:
    Andy
    So Cal
    Vehicle:
    2002 TRD
    6" lift , 35" tires , winch
    It looks like its the shifter. Lots of oil from the top on down. If I have time after work today I,ll take the boot off and g et a better look. I hope thats the problem it looks like an easy fix
     
  19. Jun 10, 2013 at 8:52 AM
    #19
    License2Ill

    License2Ill Well-Known Member

    Joined:
    May 20, 2012
    Member:
    #79174
    Messages:
    435
    Gender:
    Male
    First Name:
    Ian
    Mendocino County, CA
    Vehicle:
    SC'd 04 TRD 4x4
    Icon Ext Trvl w/ 14"x700#, LR UCA, Yukon 4.88's, front Trutrac, Dakars w/ double D6XL, Nitro LC 60065 rears, Timbren bumpstops, Manual hubs, Demello Sliders, ARB w/ Warn 9.5xp & endcap mod, CBI rear w/ swingout/boxed frame & demello plates. Rear shock relocate, U-bolt flip. 5 speed swap; hopefully soon. :)
    I had the same issue when I got my truck. It was leaking from the 4x4 shifter. Super easy fix. Just remove the two paper gaskets, make sure not to toss the thin piece of metal sandwiched between the gaskets. Clean the surface. And apply RTV. I used Toyota's red RTV.
     
  20. Jun 10, 2013 at 7:33 PM
    #20
    Andys Toy

    Andys Toy Member

    Joined:
    Jun 9, 2013
    Member:
    #105916
    Messages:
    19
    Gender:
    Male
    First Name:
    Andy
    So Cal
    Vehicle:
    2002 TRD
    6" lift , 35" tires , winch
    Well I followed the directions as posted today and LEAK GONE !!! Just a few more issues to figure out and I can go play :D
    Thanks for the detailed directions. When I went to the dealer the guy at the counter insisted there was only one gasket. So like an idiot I listened and bought one gasket. Got home took it apart and like posted there is two gaskets , so I just made one out of gasket material. Should have made both , mine is better than the original.
     
    Last edited: Jun 10, 2013
To Top