Going camping/offroading tomorrow and sure enough I walk out to my truck to see gear oil dripping from the belly skid plate.

Leak is coming from the front output seal on the t-case going to the front diff.

Remove the plate, disconnect the front drive shaft, remove the hub (got a refreshing bath of hot gear oil) and managed to pull the seal. If I am lucky enough I will find a new seal tomorrow but the bad news is I cant find my service manual.

Does anyone know if there is anything fancy or special I should do to put the new seal in? Also if anyone knows the torque settings for the drive shaft and output bolt that would be great.

Thanks in advance

 

Can't think of anything special needed to install the seal.

Other than smearing a thin coating of "The right stuff" on the O.D. As for torque on the nut, dunno, 100lbs on the bolt/nut, and 35 on the driveshaft bolts, should be sufficient.

Maybe a smear of the right stuff on the splines of the yoke too.

 

What is "the right stuff" if its grease I got plenty.

 

Companion flange nut (big one after drive shaft is out) 87 Ft-lbs

Front drive shaft flange bolts/nuts 54 Ft-lbs

Lube the seal lips with petroleum jelly and push them in with a large socket a little smaller than the outside diameter of the seal. I say them because there is a smaller seal inside the companion flage that you should change while you're in there. Both seals together from Toyota are like five dollars. Took one day to ship from another dealership. Smaller inner seal isn't a necessity if you can't get one in time, the outer one is usually the only one that goes.

 

Good quality engine sealant, like silicone sealant but much better. Use it for engine gasket sealing, around the O.D. of seals, splined shafts/yokes, etc.

It beats that copper colored stuff, the blue stuff, any of em.

"The right stuff" is manufactured by Permatex, and distributed by Napa. It is black and thick/guey. They sell a small caulking gun in a kit form with the right stuff.

It doesn't squeeze out of a tube like the others. It's really thick but does an excellent job of making anything oil/coolant tight. Will not work for fuel system sealing however.

 

Also the gear oil is 75/90, just incase ya didn't know. Available at the same place as "the right stuff", I think.

 

New seal was in stock and luckily I was able to fix it in the morning before going to work and made it on the big bear trip.

Just for archive purposes, the seal was $11 at toyota. I lubed it with a little bit of gear oil and popped it in by hand. Then took a big socket and gave it a few taps. No leaks!!!

This is an easy fix for anyone that encounters this problem. Another thread some guy said he paid $300 for it to be fixed.