KZJ71 Transfer Case

[94PRADO]

After getting my truck stuck in a large puddle last month my Prado has developed a whining noise and rumbles under acceleration, Ive noticed ive got oil leaking out of the front output of the Transfer case and also the flange has some movement in it. The oil is dark black which I assume is from water getting in?
Does anybody have a spare one available or have any advice for rebuilding them?

[imsohi]

rebuild kits are plentiful for these models only real difference in in the lay shaft size you can measure this from the back of the transfer case.35 or 38mm from memory this shaft is replaced in the full rebuild kits along with all the bearings. you will need some knowledge and tools to pull and press bearings and a 36mm socket for one of the bearing nuts. other than that take you time and you should be ok

[Clint]

If you've had water in there your oil will look like a milkshake.

I used a terrain tamer kit to rebuild mine which all went in no worries. As above you'll need a press, pullers too IIRC. One good trick is to glue the layshaft thrust washer in place with superglue so it stays in place during re-assembly. If you've got access to a hoist & gearbox jack it's just about easier to pull the whole gearbox/transfer assembly out (easy to work on with it stood on end) than to bugger around doing it in the vehicle.

PM me you email addy & I'll send you the t-case section of the workshop manual.

If you find anything seriously wrong these transfer cases are the same as most other 70 series & 60 series landcruisers so spares & parts are reasonably common. They're known as the Toyota 'Split Case' transfer box.

Also check your driveshaft universal joints - these are often the culprit if you've got driveline rumbles & vibes, the shaft wobbling around will then flog out your output bearings.

Cheers
Clint

[94PRADO]

I thought water would turn it white also, but cant explain what else would turn it black? I have a copy of the service manual thanks for the offer though. I replaced the rear U-joint and oil seal recently but the vibration my have ruined the bearings also. Im hoping to get a 2nd hand transfer case to swap in whilst I rebuild mine, good to know I may be able to get either a 60 or 70 series one

[imsohi]

I thought water would turn it white also, but cant explain what else would turn it black? I have a copy of the service manual thanks for the offer though. I replaced the rear U-joint and oil seal recently but the vibration my have ruined the bearings also. Im hoping to get a 2nd hand transfer case to swap in whilst I rebuild mine, good to know I may be able to get either a 60 or 70 series one

just be cautious there are some differences eg the 60 and 70 have different low ratios compared to the 71 and 78 series.