My yota is spilling a little gear oil. The front output shaft is leaking where the driveshaft mounts to the transfer case, and there is about 1/4 in of slop in the shaft going into the case when 4wd is not engaged (don't know if this is normal or not). I believe I am going to have to replace the output shaft bearing and seal, but don't know how big of a job I am getting myself into. Do you have to open the case to replace this bearing, or is this something you can do from the outside? The 4wd works, but I havn't tried it for long. I have been restoring this truck for the last 2 years, ran out of money for a while, now I'm finishing it. I havn't drove it for more than 2 miles the whole time I owned it. Its got the original 80 4spd tranny, and transfer case, if that matters. Thanks in advance!

 

its been awhile since Ive had a gear drive case apart, but I'm pretty sure you have to take the back half of the case off to get the front drive out, you should be able to replace the seal with out splitting the case

 

Here is a link to a Video on transfercases that Trail-Gear did. Don't think there is sound but thought that it might help you out:
http://www.trail-gear.com/videos/toy-tcase.wmv

Here is the link to the 4.7 gear install (know it is not what you are doing) but pictures help to show some of the work involved with transfer case...http://trail-gear.com/tech/470install/470inst.html