2014 Toyota Tacoma Transmission Transfer Case Leak

VIN: 5TFUU4EN9EX096520

I found no photos of the transfer case leak before June 30, 2022.

An updated digital version of this document with larger photos is available at https://todgru.com/leak

Mileage 67949 June 30, 2022

Replaced transfer case union seals, marked with red paint by the technician as a reminder to recheck at the next service appointment. Columbia George Toyota The Dalles, OR

90311-43008 Seal, Type T Oil
90311-43007 Seal, Type T Oil
96721-35063 O-Ring

Mileage 71000 (approx) September 2, 2022

I emailed Columbia Gorge Toyota these photos to ask about the red paint left for inspection reminder. The red paint could make it look wet. I'm not sure if it is leaking again at this point.

Mileage 71490 October 3, 2022

Engine Service and 120-point inspection at Morgan Automotive, Portland, OR. No mention of the leak.

Mileage 76666 January 13, 2023

Engine service, rotate tires. No leaks were mentioned. Columbia George Toyota, The Dalles, OR

Mileage 81172 July 20, 2023

Engine service. No leaks were mentioned. Columbia George Toyota, The Dalles, OR

Mileage 83622 October 10, 2023

Engine service, vehicle trip 120-point inspection, new spark plugs, fuel injection service, new rear diff fluid, new front diff fluid, new manual transmission fluid, new transfer case fluid, clean adjust rear brakes, rotate tires. No leaks were mentioned. Morgan Automotive, Portland, OR

Mileage 86160 December 8, 2023

I took these photos before the scheduled leak repair and clutch replacement at United Toyota, Imperial, CA.

Mileage 86226 December 12, 2023

Replacement clutch, flywheel, bearing, and transfer case seals. United Toyota, Imperial, CA

90311-43007 Seal, Type T Oil
90311-T0066 Seal, Type T Oil

Photos from customer service representative:

Mileage 87457 January 20, 2024

Leak photos.

Mileage 88094 February 10, 2024

Replace the aluminum transmission output cover plate and o-ring.

96721-35063 O-Ring
33121-35110 Transmission Cover
00295-01281 Form-in-place-gasket (FIPG) silicone, Transmission Cover

A service representative brought me to the shop to show the damage to the aluminum transmission cover plate and o-ring. The o-ring had been reused and had RTV to help prevent the damaged cover plate from leaking.

New cover plate and o-ring were installed. I am unsure if RTV was used with the o-ring/cover plate assembly the third repair.

This photo shows the input side of the transfer case. The technician has removed the o-ring 96721-35063. Note the nicks and scratches on the aluminum housing that holds the transfer case input shaft and oil seal.

This photo is the output of the manual transmission. See below for a close-up of scratches and RTV.

This photo is a closeup of the transmission output. The aluminum ring held by four bolts is part number 33121-35110 Transmission Cover. Notice the scratches and residual RTV inside the cover and on the output shaft.

Another closeup from a different perspective.

Mileage 89377 March 2, 2024

Engine service, rotate tires, and advise on leaking transmission/transfer case.

Advise to bring truck back on March 13th for further inspection and consulting with Toyota engineers. Columbia Gorge Toyota, The Dalles, OR

Mileage 89520 (approx) March 13, 2024

After inspection and discussion with Toyota, the service representative asked to bring the truck back at the beginning of April, when the Toyota field engineer would be onsite to determine the next course of action to repair the leak.

I plan to call on March 25th to schedule an appointed with the field engineer.