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120 Series Prado Gearbox/Transfer case oil leak

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  • 120 Series Prado Gearbox/Transfer case oil leak

    Hello everyone!

    I'm new here, as in new to Australia and new to Toyota. I recently bought a 2004 Prado 3.0 Diesel (Manual) with plenty of experience on the odometer (285,000km).

    This morning I noticed it had left me a little present on the garage floor and after some further investigation I see she's also been marking her territory in my work parking spot (being an ex-Landy driver I thought I'd be avoiding these types of things now...the excuse was always: "It's not leaking oil, it's sweating power!")

    The gearbox was replaced a few months and about 4000km ago, and it looks like the leak is coming from the gearbox-transfer case seal which is less than ideal. I reached out to the guys who did the work (they are in Queensland and I'm in Adelaide so unfortunately I can't just take it to them..) to find out about warranty and they suggested that I take it to a local shop for investigation and quotation.

    So, my questions:

    1. Any suggestions for a good independent mechanic I can take it to?
    2. Has anyone else had a similar issue? I'm guessing there is no way around splitting the whole thing and replacing the seal. I've seen some guys applying RTV around the edges but I think this is leaking a bit too much for that, and seeing as I might be able to get some financial assistance from the guys who did it, I might as well replace the whole seal/gasket.

    Click image for larger version

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    Cheers,
    Andre

  • #2
    Transfer case removes from the box pretty easily, usually it's the seal on the back of the box that leaks not the seal on the front of the transfer. Between the box and transfer is a void that the oil leaks into, sealing the face of the two is pointless as the oil will fill the void and you're still losing it from the box or transfer case whichever is leaking
    Silver '04 KZJ120~Manual~GXL~Dobinson/Kings lift~Custom valved Ironmans~Detroit Locker~Endless Air~X9 Superwinch~Madman EMS1~TJM Dual Battery~Rhino Roof Tray~120W solar panel~Foxwing awning~Bushskinz UVP~Long Ranger water tank~Bushman fridge~Steinbauer P-Box~Beaudesert 2 3/4"~Airtec Snorkel~TJM Sliders~Prico Boost Gauge~BFG-KO2s~TPMS~GME TX3420~Front and Rear Cameras~Ultimate Camper hanging off the back!

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    • #3
      To confirm I degreased the whole lot last night and can already see the oil seeping through the joint this morning. Plan is to take her in ASAP but in the meantime I just want to check the oil levels on both the transfer and the gearbox seeing as I have no idea how much has leaked out. I guess the amount of oil I have to add will also confirm weather or not it is leaking from the transfer or from the gearbox side.

      I've checked the owners manual but would appreciate it if someone can confirm what type of oil I should get.

      According to my version of the manual the gearbox needs Gear oil API GL-4 or GL-5 SAE 75W90 and the transfer case needs Hypoid gear oil API GL-5 SAE 75W90.

      What type of oil works best? Is there one type that can be used in both sides?

      (2004 3.0 Diesel, 5 speed manual)

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