RX in NC

Well done. Keep us posted on how your repair holds up as you put some miles on the vehicle.

Pinballer

Rereading my procedure. Going to do this again, the seal kept on leaking right after the repair. Probably at a slightly lower drip rate but still enough to sling oil drips onto the exhaust pipe and get small drips on my driveway. The car drives fine as it rarely goes into all wheel drive. Kind of wonder how bulletproof the transfer case is when low on oil. This time I purchased the seal from Toyota. I had previously checked the air valve on the transfer case and it moved fine. I suspect that I damaged the seal on shaft installation or maybe the shaft has some imperfections. I asked a friend what else could have gone wrong since he was involved with the design of gearboxes for jet engines and he asked if I had lubricated the seal prior to installation. That is something I did not do and will lubricate the seal to shaft mating surface this time. Also I did not inspect the shaft closely, this time I plan to inspect it closer and make sure the surface finish is very good. I may have to bring it to a polish and make sure there is no groove or scratches. I will try again, don't want to shell out big bucks to bring it to a garage. Any other suggestions or tips.

RX in NC

Good luck on your second repair attempt. Lubing the new seal prior to install is indeed a good idea. Let us know how it goes.

salimshah

Before any work, clean the area.
Ensure the spring on the old seal has come out.
Remember to scotch-brite the shaft where the seal fits. Also clean the seat area and rinse.
Use OEM and make sure the seller is authorized seller. [just to ensure the part is first quality and not a fake].
Use new clips and make sure there is no sharp edge to rip.
Seat the seal to the depth that the original was set. I use PVC fittings as cheap driver [ Don't have a socket of that dia]
Lube the seal with transmission oil. And do your best to keep the shaft level.

Salim

I try to keep the vehicle horizontal [side to side] and lower the side of the seal right before reassembly to drain a bit of trans fluid to drain out any dirt which might have entered.