4Runner Project Part 3 - Fixing a leak from the Transfer Case Actuator Motor

As the title says here we are fixing the classic O-ring and shaft seal failures.
Parts:
2 x Genuine Toyota Parts - Ring, O (90301-56009)
2 x 15x23x7 AS NBR (Colonial Seal)
1 Tube of Formed-in-Place Oil Pan Gasket
Music:
Rook1e - Solitude
Carl Storm - Flying
Phillip E Morris - Daisy
Jeff Kaale - That Day **MUTED DUE TO COPYRIGHT CLAIM**

[@joshrandall5297]

Thanks for the info. It takes balls to that in your driveway.

[@boundlessbuilt943]

It definitely takes some will power and motivation.

[@Asian_Connection]

Keep it up, your video will help alot of people. Thank u

[@boundlessbuilt943]

Thank you! I appreciate the feedback.

[@bmwfizix1]

I also doubled the seal for my 2004 V8 4Runner Sport when I completed this in 2009. I wish there was a video at the time. I had a Toyota service manual which was very helpful. Still...it takes some courage!

[@boundlessbuilt943]

I was definitely dreading it. Unfortunately the motor itself is seized so I’ll be doing this over again with a new actuator motor or FJ tcase swap. Still weighing the two options.

[@jamesward1801]

Dude, please make another video that I can follow along step-by-step when you do this 🙏🏻

[@jamesward1801]

Nevermind, just realized this is not a new video- my bad

[@boundlessbuilt943]

I have an actuator ready for install but I blew the motor on my other car so that’s taking priority but the actuator is something I want to do a video on.

[@jamesward1801]

@@boundlessbuilt943 That would be amazing! I'm just going to live with the leak for a year or so, and then I'll probably just replace the whole actuator since I have a 2004 and I know it will probably seize up

[@blakes9526]

Beauty! thanks for making this video!

[@boundlessbuilt943]

Thanks for checkin it out!

[@nathanpierce6175]

Thanks for the video. Getting ready to tackle mine. I really appreciate you taking the time to post this.

[@boundlessbuilt943]

Thanks for watching! Let us know how it goes. I’m interested to hear what challenges other people run into.

[@nathanpierce6175]

@@boundlessbuilt943 Absolutely. I also did the X-REAS delete and it was pretty straight forward. Used a suspension kit from AllDogs Off Road and have been really happy with it. Did front wheel bearings while i was in there.

[@boundlessbuilt943]

Sweeeeet! I just did the XREAS delete as well. Went with Fat Bobs Garage kit. My axles were toast so I swapped those out. Looking back I kind of wish I did the wheel bearings while I was in there. I have so much to do... lol

[@nathanpierce6175]

@@boundlessbuilt943 Were you ever able to get the truck to shift between 4H and 4L reliably again?

[@boundlessbuilt943]

@@nathanpierce6175 I got it to move one time and then I had some trouble getting back into H4. But I believe my actuator got some water in it because the breather hose was complete off the the actuator so I think I just need to exercise it. I know the motor isn’t seized at this point but I’ve been trying to wait for warmer weather to move the actuator around - I have read that the tcase doesn’t like cold weather and unfortunately the high today is 28 here.

[@em2965]

Good stuff man, I have a 2000 third gen 4Runner, and am looking into picking up a 4th gen V8 one also. There’s not nearly as much information available on these 4th gens as there is on the 3rds haha it’s nice to see.

[@boundlessbuilt943]

Thanks man! Agreeed. Look out for the cracked manifolds and leaky transfer case actuators. Otherwise everything is easy. This one had both but it was worth it. We love it!

[@em2965]

@@boundlessbuilt943 yea, honestly I’m okay with the cracked manifolds, just means I might as well put some headers on it

[@boundlessbuilt943]

@@em2965 Agreeeeed! I’m waiting on my Doug Thorley long tube headers as I type. Can’t wait.

[@geneofone]

My 2003 4Runner just had the same leak at the actuator. I bit the bullet and had my mechanic do the work. They replaced the actuator. Cost was $2900. If I did not have a V8 I would have probably sold it as is but with 240k miles I believe it will last a bit longer.

[@boundlessbuilt943]

These things are so durable that I think you made the right choice! I love mine, totally worth the blood sweat and tears LOL

[@GregGomez1000]

Godspeed bro

[@sonicfray]

Did you ever get the shifting between high and low working? Eager to hear about how you resolved that. Thanks for the video- I have to do this same thing but am weary to do it if I can't get the shifting on my 04 v8 4wd not working.

[@boundlessbuilt943]

I got it to go into 4lo without flashing on the dash but the gear wouldn’t engage. It’s grinding still. I’m confident it’s not something I did during this process but rather the actuator itself. A lot of people buy a new actuator if theirs is actually seized. I did not. In hindsight, that might have been the better choice. I’m still working it.

[@williamb2854]

Saw another guy...showing how to time the actuator. My guess ...its not timed correctly. Check that out...

[@victorporoshine8131]

Awesome video! Mine is messed up as well......

[@boundlessbuilt943]

You gonna tackle yourself?? It’s not too bad.

[@victorporoshine8131]

@@boundlessbuilt943 with your video I think I can do it. With the new actuator what position do you put the 4hi/lol switch in before starting? Not sure if I can confuse the indicator

[@boundlessbuilt943]

Thank you! Keep it in 4hi and they you can cycle it when you get it all back together

[@davidpimentel3926]

Hey man hopefully you reply, where did you get the little o ring seals for the rods on the actuator. I can not find those anywhere.

[@boundlessbuilt943]

Ask and ye shall receive! I ordered mine directly from Colonial Seal Company. The invoice has it as item: “OS 15x23x7 ASN” and the item description is: “15x23x7 AS NBR”. They were $3.45/ring. I ordered 5 just to be safe.

[@chad_smith]

I like the 3 parter here. Thank you for not throwing up a hour long video. Haha I’ve got to replace my whole T-Case, the tech said he would have to drop the whole transmission to replace it. Is there a difference between replacing a v6 vs v8 t-case?

[@boundlessbuilt943]

Hahaha, I hate long videos!! So the service manual says to do it that way, so most mechanics will do it that way. You MIGHT be able to find someone that will bypass the transmission removal but that might be a long shot.

[@chad_smith]

@@boundlessbuilt943 yeah he works for a dealership and if he's doing the work, the dealerships name is on the work... I dont think he's going to bypass it :( Thank you for the insight!

[@russmt4181]

You do not have to remove transmission. The v6 transfercase is different from the v8 transfercase.

[@henryhoang2145]

Do you happen to have the part number for the two small actuator rod oil seals that you had to pick out? The parts diagram on toyota's site doesn't show them. Thanks for the video!

[@boundlessbuilt943]

Toyota doesn’t sell them individually, they encourage you to buy the whole actuator. I ordered mine directly from Colonial Seal Company. The invoice has it as item: “OS 15x23x7 ASN” and the item description is: “15x23x7 AS NBR”. They were $3.45/ring. I ordered 5 just to be safe. Thanks for the feedback!

[@jamesward1801]

I bought a 2004 V8 from a small used car dealership 4 days ago. Just discovered this leak about an hour ago 🫠 Trying to decide if I want to take this job on… it would be the beastliest job I’ve done yet by far… woof

[@boundlessbuilt943]

@jamesward1801 If I can, you can.

[@russmt4181]

I've been thinking about engineering a bolt on kit to convert these to a cable operation and get rid of the actuator motors. I'm not sure if there would be enough interest to bother making them.

[@boundlessbuilt943]

I think there would be. A lot of people do the FJ transfer case swap because it’s quite similar in size and bolts up. You have to have a body lift and change your drive shaft though.

[@wilfredocarracelas7351]

Tha is exactly what I think about my v8 , do something like replace it on a manual transfer case mode 😮.

[@russmt4181]

@@wilfredocarracelas7351 just a couple months ago I did the fj transfercase swap. Was pretty easy.

[@markharris9055]

I have a 04 limited edition 4Runner and it’s leaking as well but I don’t have the manual. I see you said it was great help. Can you give me any advice before I begin tearing it down. It looks like a big job. How long did it take you to complete?? Any advice will be much appreciated

[@boundlessbuilt943]

Everyone says it takes anywhere from 5-7hrs. I let my liquid gasket cure for a day because it was 20ish degrees and I was worried it wouldn’t dry properly so it took 2 days total but probably only 7hrs of actual labor. If I were to do it again I would I replace the whole actuator (mine is seized). Also I would have taken the time to make a jig/stand for the jack to keep the tcase at the right angle. The field service manual is on the internet, you can find it on t4r forums stickied at the top of the 4th gen subsection. Is there any part you are confused or worried ab?

[@markharris9055]

@@boundlessbuilt943 how was it once it was apart?? Is all the gears locked into place? Mine isn’t seized up the seal is just leaking. Was yours seized up when you starter? It changes from hi to low without any problems right now I have a break line busted and it’s on jack stands now. I was looking at it all

[@boundlessbuilt943]

@@markharris9055 I didn’t move it when it was off because I didn’t want to throw it out of timing and then have to worry ab retiming it. It did not engage properly prior to new seals - why I should have just changed the whole actuator. I think you just need the o ring(s) and seals. When reinstalling the actuator back onto the tcase, be gentle because you don’t want to crack the housing of the actuator.

[@chrishipskind6203]

Thx for the video.. I have a slow leak. in those seals. I am tryin to decide if I want to buy a low mile transfer case or do what you did.. suggestions?

[@boundlessbuilt943]

The transfer case swap would be significantly easier but the seals might be bad on the one you buy as well. It’s kind of a gamble. But it’s not bad to have a back up case and actuator that you can service while still using your 4R.

[@chrishipskind6203]

@@boundlessbuilt943 yea.. that's true..Thank you again for generously sharing a difficult challenge.. takes guts to even tackle the problem and more to show the world... cheers!

[@boundlessbuilt943]

I appreciate it!! If I can do it, you can!

[@chasepeterson7854]

Hey idk if my 4Runners the same I have a 2004 Toyota 4Runner 4wd v6 and the transfer case is leaking will I have to do this, or is it like the Lexus gx’s where you can just pop the actuator out?

[@boundlessbuilt943]

V6 is different, you might be able to get away with the easy route but I can’t say for sure. Toyota-4Runner.org forums would have an answer for you

[@TheDesertRat31]

So if I read the comments correctly. You have a new Aisin actuator that will be installed? And your transfer case wasn't shifting correctly before the seal replacement?

[@boundlessbuilt943]

Correct. I’m still trying to find time to do the swap.

[@boundlessbuilt943]

Not yet, my other car got smashed by a deer so I’ve been fixing that myself.

[@tatales]

Hello I am about to tackle this job how is the seals holding up? What are the links to the products you bought?

[@boundlessbuilt943]

I don’t have the link but the invoice has it as item: “OS 15x23x7 ASN” and the item description is: “15x23x7 AS NBR”. They were $3.45/ring. I ordered 5 just to be safe.

[@jakemir]

9:27 can these spring seals be replaced when the pins are not installed?

[@boundlessbuilt943]

If you take the rods out you are throwing off the ‘timing’ of the gears in the actuator. I do not recommend removing them unless you plan on timing your actuator.

[@DP-ke3vf]

Your a brave man! My son has a 2007 4runner that we switched to 4hi and now it won't go back into 2 wheel drive. When we select to 4low it will not actuate to 4low but just stays in 4hi. Does any have an idea how we can get this back in 2 wheel drive. The green 4x4 and orange 4x4 are lit up but only the orange one blinks so I was wonder if you thought it might be related to the front actuator.

[@boundlessbuilt943]

I’d go check on Toyota-4Runner.org forums. They have a lot of info on this. Particularly for your sons setup.

[@DP-ke3vf]

@@boundlessbuilt943 Thanks a lot, Did you get your shifting correctly?

[@boundlessbuilt943]

@@DP-ke3vf Mine is completely seized in 4hi but I have only 4hi or 4lo so it’s not unusable. I do have a new actuator on deck but I’m waiting for the weather to warm up

[@DP-ke3vf]

@@boundlessbuilt943 I think that you can change the actuator without pulling the transfer case. You will just have to disassemble the actuator install over the shafts and then reassemble in time. The timing is not very complex at all.

[@boundlessbuilt943]

@@DP-ke3vf I have heard that but everything I’ve read ab timing it seems like a pain in the ass. I’m on the fence ab it

[@UselessMedia1]

Hey, 05 v8 4runner owner here...blew my trans(grinding in every gear). Swapped a used one in no more grinding but once I drive wouldn't move at all. Took my transfercase apart and everything internal seems fine and tested the actuator both 4hi/4lo and center lock is working. Is it possible the 4hi/4lo could have been in some in-between state and made it act as if the transfer case was in neutral?

[@boundlessbuilt943]

Very possible. I’d get all 4 wheels off the ground and see if you can work the actuator.

[@UselessMedia1]

@@boundlessbuilt943 got all 4 wheels off the ground and I am able to switch between 4hi/4lo. Still no luck with moving or spinning wheels switching between any gear in the transmission. Center diff lock is engaged and won't come out. But even then I should still be able to have with that engaged.

[@boundlessbuilt943]

@@UselessMedia1 It may sound trivial but I’d double check your fluid level for both tcase and trans. If those are good id probably check the shift solenoid. I’d also be scouring the t4r forums like mad - might be documented there.

[@emarquis87]

Just and honest question ive heard people have to do this to reseal.... but i just saw another video of a guy pulling the actuator off Tcase in place pull it off the high low and case lock shafts and place it back on (for an actuator swap) and it was successful... is this not possible or something? seemed to work for him... also i was just watching to see what would be needed to replace the output shaft seals or if this can be done with the Tcase in place

[@boundlessbuilt943]

I have heard it is possible from a few people but I have not done it myself so I can’t say for sure. If the tcase actuator comes off the seals will come with it.

[@emarquis87]

@boundlessbuilt943 good deal and just fyi for your tcase seal next time you can use maybe a 1/4 or 1/3 of the silicone about a 1/16 of an inch even on flat to flat metal surfaces works mint not that excess pushing into the tcase would honestly hurt anything no oil pump

[@vitaliyalbertov771]

Hi I just called Toyota dealer they said they don’t sell shaft seals could you tell me where did you get them from?

[@boundlessbuilt943]

I ordered mine directly from Colonial Seal Company. The invoice has it as item: “OS 15x23x7 ASN” and the item description is: “15x23x7 AS NBR”. They were $3.45/ring. I ordered 5 just to be safe.

[@slprime]

Newbie question: is standard to let the seal dry for hours when reinstalling it? Thanks!

[@boundlessbuilt943]

The seals that I replaced don’t need any drying time, they are good to go once you have replaced them. The liquid gasket that seals the transfer case has a drying process.

[@slprime]

@@boundlessbuilt943 Thanks!

[@jxl0318]

Do you have the Toyota part number for the colonial seal/shaft oil seal? I went into Toyota and they couldn’t find me the part

[@boundlessbuilt943]

No Toyota part number. They want to sell you the whole actuator. I ordered mine directly from Colonial Seal Company. The invoice has it as item: “OS 15x23x7 ASN” and the item description is: “15x23x7 AS NBR”. They were $3.45/ring. I ordered 5 just to be safe.

[@jxl0318]

@@boundlessbuilt943 thanks for responding. I’ll look into it and get me a few.

[@scottferguson3505]

Where did you find the seals for the actuator shift rods? I’ve looked everywhere but no one can give me a part# or it’s always different than the one I have.

[@boundlessbuilt943]

I ordered mine directly from Colonial Seal Company. The invoice has it as item: “OS 15x23x7 ASN” and the item description is: “15x23x7 AS NBR”. They were $3.45/ring. I ordered 5 just to be safe.

[@automotivejunkie7868]

I serviced the gasket on my actuator on my 06 sequoia however I did not remove the entire transfer case I just opened the actuator box and remove the gears and took it off

[@boundlessbuilt943]

Did you have to “time” the gears?

[@boundlessbuilt943]

All time 4wd (with hi and lo selector) and a locking center diff?

[@geovanymadrid6478]

Where you able to set the timing of the gears in the transfer case actuator? As far I know, ones you pull the transfer case actuator out, there's no way to set it back unless you pull the entire transfer case from the transmission!

[@boundlessbuilt943]

My understanding is that you don’t have to time it this way.

[@geovanymadrid6478]

@@boundlessbuilt943after I had a blinking light on my dash all the time with a beep every time when I try to make my 4lo work, I decide to pull my transfer case actuator gear apart because was jammed So after looking for a lot of information I got it on time and my 4hi works good but not my 4lo After that I decide to pull the entire transfer case actuator with out the long pins in it I've been trying to set back, but to me there's no way to set back unless taken my entire transfer case from the transmission Sorry for my English spelling

[@jacobstiltner9387]

Did you ever get the 4 low and everything figured out?

[@boundlessbuilt943]

Not yet! The actuator is seized. I’m going to install a new actuator but first I’m gonna test out some alternatives before I do.

[@spikeware3774]

kzbin.info/www/bejne/bpPPmquIhrlnsLM

[@spikeware3774]

@@boundlessbuilt943 kzbin.info/www/bejne/lWfXhntqbrl5mdk

[@boundlessbuilt943]

I was definitely considering this route. I couldn’t find one at the time but I agree it takes a lot of steps out of the process. I ended up buying a Aisin one and it’s waiting to be installed. My FRS is down right now because of a deer so I’m collecting parts for it - once I get it moving again I’ll do the swap. Thanks for the input!

[@wilfredocarracelas7351]

Today feb12/2024 I try to pull out the atuator on my toyota 2003 v8 all wheel drive and. surprise! CAN'T DO it 😢

[@boundlessbuilt943]

Daaang, what’s the problem??

[@user-yk382p53jh]

I have a same leak. I thought I just needed o-rings changed and I found I was right after paying toyota 160bucks to inspect. they found other 2leaks and charged me about $1550 just for actuator o-ring exchange. I thought it was too much and now I look at your video I might just go ahead and pay them for this job. That is a great video but I don't think this is a job for guy like me who doesn't know much about car.

[@boundlessbuilt943]

It’s definitely a challenge if you don’t wrench on cars much. Hope they take care of you

[@user-yk382p53jh]

@@boundlessbuilt943 thanks. Questuon, I am thinking leave it as it is until I find better deal for service. Can I just top it up with lucas gear oil with turkey baster? Gonna leave drip pan under.

[@boundlessbuilt943]

@@user-yk382p53jh I would say save the money and throw some decent 75w90 gear oil in there - also they sell the hand pumps that just attach to the top of the oil containers which would fill it really easily/quickly.

[@user-yk382p53jh]

@@boundlessbuilt943 thanks. I have very few like you whos saving money and life. I might just live like this. Top it up once a month. Im sure the o ring gonna fail again and again...

[@boundlessbuilt943]

@@user-yk382p53jh It can be a challenging way of life but if you keep at it, you’ll save yourself some money (hopefully) and get it right eventually.

[@williamb2854]

Just sharing...another KZbinr..showed me that the 4 wheel drive lever flange gasket was an issue with leaks.. 4 bolts...2 gaskets...leak issue resolved. Remember to change out the gaskets...just saying.

[@boundlessbuilt943]

Thanks for sharing, the more everyone knows the better.

[@firebir11]

Don’t touch anything, it’s Toyota’s rustinhibitor fluidynamic recalliliminator.

[@boundlessbuilt943]

Don’t know if I should laugh or cry... lol

[@firebir11]

@@boundlessbuilt943 I own a 4Runner, it’s a very nice truck. I hope you got your 4hi/4low working ok.

[@boundlessbuilt943]

Agreeed. Thank you, unfortunately the actuator is seized so I’ll be doing this over again. LOL

[@iknowbobmiller5412]

Hey, just wondering if you ever figured out the problem with the problems you were having after you finished? I saw this one video about the actuator itself and there is a red dial inside that needs to line up and I was wondering if that could have been your issue. The guy stted that if it's not lined up you will get an error and trouble changing from 2 - 4H -4L kzbin.info/www/bejne/fXS8Y3V5mdGIaqs

[@boundlessbuilt943]

So I have an all time 4wd 4Runner so I only have the high and low options. 4Lo is still not working I have a new actuator on standby because I believe this one is seized but I blew the motor in my commuter and I’ve been workin on that so I don’t have the downtime to do the actuator on 4runner yet

[@jakemir]

I replaced with a new Asin DAT-003 so it was already setup but I had to remove the rods to install it in mine and the spring orings fell out 4Runner Asian SAT-003 4WD Actuator Replacement Full Video 36410-60093 kzbin.info/www/bejne/rnzKc5KNedOnqrM

[@boundlessbuilt943]

Gotcha, so you just left the transfer case in place and the rods in there. Then those spring seals will go in between the actuator and tcase just make sure they are oriented right