Drivetrain - ATF/Gear Oil leak From Transfer Case Vent
T-SB-0138-10Rev1
May 28, 2010
Transmission Fluid or Gear Oil Seepage from Transfer
Case Vent (AWD)
Service Category
Drivetrain
Section
Transfer/4wd/Awd
Market
USA
Applicability
TSB REVISION NOTICE
July 19, 2010 Rev1:
^ Warranty Information has been updated.
Any previous printed versions of this service bulletin should be discarded.
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. TC008-07.
^ Applicability has been updated to include 2007 - 2009 Highlander, 2001 - 2005 RAV4, and 2007 - 2010 Sienna vehicles.
TSB No. TC008-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding.
Introduction
Some 2004 - 2009 model year Highlander 2001 - 2005 model year RAV4 and 2004 - 2010 model year Sienna AWD (4WD) vehicles may display a transmission fluid or gear oil seepage from a vent on the right side of the transfer case. The seepage is from the transfer RH (right-hand) bearing retainer No.2 oil seal. Production improvements have been implemented to prevent this condition from occurring. Follow the repair procedure in this bulletin to replace the RH bearing retainer No.2 oil seal assembly.
Production Change Information
This TSB applies to 2001 - 2005 RAV4 and to Highlander and Sienna vehicles produced BEFORE the Production Change Effective VINs shown.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Parts Information
Required Tools & Equipment
Components
Repair Procedure: Removal
1. Confirm source of gear oil/transmission fluid seepage is from vent on RH bearing retainer.
2. Remove the engine assembly with transaxle.
Refer to the Technical Information System (TIS) applicable model and model year Repair Manual:
3. Remove the automatic transmission w/transfer.
Refer to TIS applicable model and model year Repair Manual:
4. Remove the transfer case No.1 plug and remove the gasket from the plug.
5. Remove the transfer drain plug and remove the gasket from the drain plug.
6. Remove the transfer assembly.
A. Remove the 2 bolts and 6 nuts.
B. Using a plastic hammer drive out the transfer assembly from the transaxle assembly.
NOTICE
^ Disconnect the transfer assembly from the transaxle assembly without tilting.
^ When moving the transfer assembly, do NOT hold the assembly by the oil seals.
7. Remove the transfer cover gasket from the transfer assembly.
8. Using the SST remove the transfer RH bearing retainer oil seal.
SST P/N 09308-00010
NOTICE
Be careful NOT to damage the oil-seal-fitted surface of the retainer.
9. Remove the transfer RH bearing retainer sub-assembly.
A. Remove the 7 bolts from the RH bearing retainer sub-assembly.
B. Using the SST make a clearance between the RH bearing retainer sub-assembly and the transfer case.
SST P/N 09950-00020
C. Remove the SST.
D. Using the SST, remove the RH bearing retainer sub-assembly from the transfer case.
SST PIN 09520-10021
10. Remove the two 0-rings.
Using a plastic pry tool or equivalent remove the two (2) 0-rings from the RH bearing retainer.
NOTICE
Be careful NOT to damage the retainer's groove for the 0-ring.
11. Remove the center differential case tapered roller bearing RH (outer race).
A. Hold the RH bearing retainer in a vise.
B. Using the SST remove the outer race washer and No. 2 oil seal from the RH bearing retainer.
SST PIN 09308-00010
NOTICE
Be careful NOT to damage the oil-seal-fitted surface of the retainer.
Repair Procedure: Installation
1. Install a NEW No.2 oil seal in the RH bearing retainer.
2. Install the transfer RH bearing retainer oil seal No.2.
A. Using the SST and a press install the oil seal No.2 to the RH bearing retainer.
SST P/N 09950-60010 (09951-00360, 09951-00540, 09952-06010), 09950-70010 (09951-07150)
NOTE
Carefully press4it so that the oil seal is NOT tilted.
B. Apply a small amount of MP grease No.2 to the oil seal lip.
3. Install the transfer ring gear mounting case washer No.2 to the RH bearing retainer.
4. Install the center differential case tapered roller bearing.
Using the SST and a press install the outer race to the RH bearing retainer.
SST PIN 09950-60010 (09951-00620), 09950-70010 (09951-07150)
5. Install the 0-rings.
A. Apply Hypoid gear oil to the two NEW 0-rings.
B. Install the two (2) 0-rings to the RH bearing retainer.
NOTICE
Be careful NOT to twist the 0-ring and fit it into the retainer's groove properly.
6. Install the transfer RH bearing retainer sub-assembly.
A. Place the transfer case with the face where the RH bearing retainer is to be installed facing up as shown in the illustration.
B. Center-align the center differential control coupling assembly and the case.
C. Apply MP grease No.2 thinly to area A as shown in the illustration.
HINT
Apply MP grease No.2 to prevent the oil seal lip from rolling back.
D. Insert the SST into the transfer RH bearing retainer sub-assembly.
SST P/N 09387-00090
NOTICE
Insert the SST straight in order NOT to damage the oil seal.
E. With the SST and the transfer RH bearing sub-assembly in close contact install the transfer RH bearing retainer sub-assembly together with the SST into the transfer case.
NOTICE
^ Avoid interference between the case and the retainer and between the SST and the transfer ring gear mounting case.
^ Carefully check the retainer's 0-ring for damage and incorrect fitting.
F. Make sure that the transfer RH bearing retainer sub-assembly and transfer case contact closely
G. Tighten the 7 bolts evenly in the order shown in the illustration.
Torque: 28 N*m (286 kgf*cm, 21 ft*lbf)
H. Remove the SST.
7. Inspect total preload.
A. Using the SST and a torque wrench measure the initial torque between the driven pinion bearing and the ring gear face.
SST P/N 09326-20011
Torque:
Used Bearing:
Driven Pinion Preload +0.15 - 0.30 N*m
(+1.6 - 3.1 kgf*cm, +1.3 - 2.7 in*lbf)
HINT
Use a torque wrench with a fulcrum length of 160 mm (6.30 in.).
NOTE
Measure the torque after rotating the bearing in both clockwise and counterclockwise directions to make it fit.
B. If the preload is too large replace the bearing spacer with a NEW one.
C. If the preload is too small repeatedly adjust the preload by tightening the lock nut 5 - 10 degrees at a time until the standard value is obtained.
D. If the preload is insufficient even though the tightening torque of the lock nut exceeds the maximum of the standard value loosen the lock nut and apply gear oil SAE 90 (GL-5) to the lock nut and the screw thread and base of the driven pinion. Then repeat the preceding operation. If the tightening torque is smaller than the standard replace the bearing spacer with a NEW one and adjust it.
SST P/N 09326-20011, 09556-16030
Torque: 378 N*m (3855 kgf*cm, 279 ft*lbf)
8. Install the transfer RH bearing retainer oil seal.
A. Using the SST drive the oil seal into the RH bearing retainer to the position shown in the illustration.
SST P/N 09223-46011
Drive in the oil seal carefully so that it will NOT be tilted.
B. Apply MP grease to the oil seal lip.
9. Install a NEW transfer cover gasket to the case.
10. Install the transfer assembly.
A. Apply FIPG sealant 1281 to the transaxle assembly and the transfer assembly in continuous beaded form of 1.2 mm (0.05 in.) diameter as shown in the illustration.
FIPG sealant: Three Bond 1281, or equivalent
B. Install the transfer assembly to the transaxle assembly with the 2 bolts and 6 nuts.
Torque: 69 N*m (700 kgf*cm, 51 ft*lbf)
NOTICE
^ Check that the gasket is installed to the transfer assembly before instaling it to the transaxle assembly.
^ Install the transfer assembly to the transaxle assembly without tilting.
^ When moving the transfer assembly, do NOT hold by the oil seals.
11. Install the automatic transmission w/transfer.
Refer to TIS applicable model and model year Repair Manual:
12. Install the engine assembly with transaxle.
Refer to TIS applicable model and model year Repair Manual:
13. Install the transfer drain plug with a NEW gasket.
Torque: 49 N*m (500 kgf*cm, 36 ft*lbf)
14. Install the transfer case No. 1 plug.
A. Add oil up to the level 0 - 5 mm (0 - 0.20 in.) below the lowest end of the plug hole.
Oil quantity:
0.95 U.S. qts (0.9 L, 0.71 Imp. qts)
NOTE
Add oil slowly.
B. Install the No. 1 plug with a NEW gasket.
Torque: 49 N*m (500 kgf*cm, 36 ft*lbf)
15. Inspect and adjust front wheel alignment.
Refer to TIS applicable model and model year Repair Manual:
16. Check the ABS speed sensor signal (ABS with EBD & BA & TRAC & VSC system).
Refer to TIS applicable model and model year Repair Manual:
17. Re-initialize any affected power Systems.
Refer to TIS for the applicable TSB or Repair Manual section.