Repairing Manual 2004–2009 Toyota Highlander Transmission Fluid or Gear Oil Seepage from Transfer Case Vent
Some 2004 – 2009 model year Highlander, 2001 – 2005 model year RAV4, and 2004 – 2010 model year Sienna AWD (4WD) vehicles may display a transmission fluid or gear oil seepage from a vent on the right side of the transfer case. The seepage is from the transfer RH (right-hand) bearing retainer No. 2 oil seal. Production improvements have been implemented to prevent this condition from occurring. Follow the repair procedure in this bulletin to replace the RH bearing retainer No. 2 oil seal assembly. Repair Procedure: Removal 1. Confirm source of gear oil/transmission fluid seepage is from vent on RH bearing retainer. 2. Remove the engine assembly with transaxle. Refer to the TechnicalInformation System (TIS), applicable model and model year Repair Manual: • 2004 Highlander: Engine/Hybrid System – Engine Mechanical – “2AZ-FE / 3MZ-FE: Partial Engine Assy: Replacement”
4. Remove the transfer case No. 1 plug and remove the gasket from the plug. 5. Remove the transfer drain plug and remove the gasket from the drain plug. 6. Remove the transfer assembly. A. Remove the 2 bolts and 6 nuts. B. Using a plastic hammer, drive out the transfer assembly from the transaxle assembly. NOTICE • Disconnect the transfer assembly from the transaxle assembly without tilting. • When moving the transfer assembly, do NOT hold the assembly by the oil seals. 7. Remove the transfer cover gasket from the transfer assembly. 8. Using the SST, remove the transfer RH bearing retainer oil seal. SST P/N 09308-00010
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