holycowe

No, that little plastic gear and the short shaft fell off in the pic. Put em back before close it

470reasons

Anyway, my idea for installing a split o-ring would go like this:

Clean the area super clean.
Hold one end of the o-ring to the actuator with a couple tabs of glue dots. (Used to hold posters to a wall)
Put a very very small drop of super glue on the free end and shake off any excess glue.
Use tweezers to bring the ends together and gently hold in place for about 45 seconds.
Apply Permatex Ultra Black RTV in the channel on both sides of the o-ring at the splice maybe for about 3/8" on either end of the splice. RTV should be in the channel and not protrude any higher than the o-ring.
Let sit for at least 12 hours.
Lubricate o-ring and slide actuator back into the housing.

The idea is to use the super glue to hold the o-ring together temporarily while the RTV is being applied and is curing. The long term strength is provided by the RTV applied around the splice.

In the picture below, the RTV would fill the channel on both sides of the o-ring in the area between the glue dot and tweezers.

DISCLAIMER:
I have never done this on an actual vehicle. This information is provided for amusement purposes only. Use at your own risk.

holycowe

Oh, ok. You know that gear fell off on my pic

470reasons

LOL!

Let us know how the repair went.

There isn't any pressure on the gear oil, so all the o-ring and RTV have to do is hold the oil in the case. RTV could do the trick.

At least you won't screw up the xfer case trying this method!

holycowe

We already done hours ago. Will keep an eye on it next few days to see any oil dripping.

kh91466

I too experienced the transfer case leak on my 2003 4runner V8. I ended up at my Toyota dealer who split the case and found the o- ring and the two seals around the shafts bad. Even though the Transfer Drive Actuator worked fine and there was no oil inside due to the bad seals they replaced the Drive Actuator with a new one. [OUCH] They returned my used Drive Actuator to me. Now I have a perfectly good Transfer Drive Actuator that only needs an o-ring and two seals. Guess I'll keep it in case someone needs it.

burny

Mind telling what that job cost you?

LVLEXUS

ZERO.....

Even though the GX 470 is way out of warranty..I was able to get this issue fixed for FREE!!!!

BlackCat81

A TSB does not mean it's covered under warranty. A TSB is simply a diagnostic aide for technicians to perform repairs on possible common issues with vehicles. As an Infiniti tech, we have bulletins for everything from chrome wheel care to extended storage procedures, as do all car manufacturers. No TSB's imply extended warranty coverage unless specifically noted, but some dealers goodwill repairs for client satisfaction.

And TSB is Technical Service Bulletin, not Toyota Service Bulletin.

BlackCat81

Mine had the repair done before I purchased it. It was was $2,300.

LVLEXUS

I CLEARLY UNDERSTAND WHAT A TSB MEANS and WHAT IT DOES NOT MEAN.....

I was just referring to the fact that my GX is out of warranty and that Lexus took care the problem/issue....WITHOUT A HASSLE!!!!!



Some dealers goodwill repairs for client satisfaction!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

BlackCat81

Yes, you might understand what a TSB is for, but this is a forum for people to come to who may not know what it means, hence my explanation and clarification of what someone thought was a "toyota service bulletin." Miss information spreads like wildfire, and in my humble opinion, this forum has a lot of it. If someone like me, who does work like this for a living and has made a career out of it can clarify some things, then I have no problem doing it.

chiph9

Yep, a TSB is just an advisory to the service departments. It doesn't even have to be for anything functional. I've seen TSBs from Honda that are basically reminding the techs of the proper way to do something -- not to reuse clips which are designated as "single-use"

Chip H.

Jimlevin

So, has anyone actually performed the repair successfully by removing the module without opening the transfer case AND then ALSO been able to go from hi range down to low range and then back to high with no issues? I ask because I did not see anyone who completed the repair and then also tested going from high range into low range, after the repair was complete and reported no issues (unless I missed a post).

470reasons: did you ever try to go from high range into low range and then back to high again like you said you were going to try in the dealership parking lot?

Any info post repair from anyone, I would appreciate. I would like to do this myself but I am worried that the synchronization will be off and I will not be able to go into low range and I want to keep low range available on my 2004 GX470.

Thanks, this is a very frustrating issue for a $0.50 seal!

Jimlevin

Update December 2014:

Well, as much as I didn't want this problem, a small local specialty shop that employs Lexus certified mechanics fixed the leak by only removing the box, total cost $344.00. I thought the risk of damage was just too high to do it myself. They also replaced most of the transfer case fluid.

Dealer quoted me $1,204.00 (same dealer who I bought it from but I don't trust their estimates, they always estimate low and the bill is always, at least, double their estimate).

Works perfect now in 4HI and 4LOW after the repair, no more leaks.

The shop did tell me that a lady came in 2013, with the exact same problem, only worse. Quick oil change place found the leak and had told her to "just watch the leak, it's so small there's no need to worry about it"-- WRONG! Her transfer failed within a few weeks of her visit to the oil change place and locked up because of a lack of fluid, total repair cost was $9,200 to replace the transfer case and other damages.