ATF Leak from Transfer Case

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1 T-SB November 3, 2008 Service Category Drivetrain Section Transfer/4wd/Awd Market USA Applicability YEAR(S) MODEL(S) ADDITIONAL INFORMATION 2008 Highlander Drive Type(s): 4WD Engine(s): 2GR Transmission(s): 5AT VDS(s): ES41A, ES42A, ES43A Sienna Drive Type(s): 4WD Engine(s): 2GR Transmission(s): 5AT VDS(s): BK22C, BK23C, BK29C Introduction Some customers may complain about a red fluid leaking from the transfer case vent on top of the transfer case or between the transfer case and transaxle. The root cause of this issue is related to damage to an O-ring during the transfer case assembly process allowing automatic transmission fluid (ATF) to enter the transfer case during vehicle operation. Production countermeasures have been implemented at the transfer case supplier. Replacement of the transfer case assembly will be required to repair the vehicle. NOTE This condition is an assembly-related issue and will most likely appear prior to 5,000 miles of use. Production Change Information This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown below. MODEL Highlander Sienna PRODUCTION CHANGE EFFECTIVE VIN JTEES4#A* TDBK2#C*9S Page 1 of 5

2 T-SB November 3, 2008 Page 2 of 5 Warranty Information OP CODE DESCRIPTION MODEL TIME OFP T1 T R & R Transfer Assembly 8.7 Highlander Combo K Add: Air Conditioning R & R Transfer Assembly Combo K Add: Air Conditioning Sienna 0.2 Combo L Add: Power Steering 0.5 APPLICABLE WARRANTY This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle s in-service date. Warranty application is limited to correction of a problem based upon a customer s specific complaint. Parts Information MODEL PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME Highlander Same 1 Transfer Assembly Sienna Same ATFWS Same ATF WS As Needed QTY Required Tools & Equipment SPECIAL SERVICE TOOLS (SST S) PART NUMBER QTY Drive Shaft Nut Chisel* Drive Shaft Remover Attachment* Differential Side Gear Shaft Tool Front Hub Bearing Adjusting Tool* * Essential SST. NOTE Additional SSTs may be ordered by calling SPX/OTC at Hypoid Gear Oil SAE 90 (GL-5) REQUIRED TOOLS & MATERIAL QTY 0.95 U.S. qts (0.9 liters)

3 T-SB November 3, 2008 Page 3 of 5 Repair Procedure 1. Identify source of red fluid leaking from vehicle. A. Is red fluid leaking between the transfer case and the transaxle assembly? If YES This TSB applies Go to step 3. Figure 1. Location of Transfer Case Leak in Vehicle 1 Transaxle Assembly 2 Transfer Assembly 3 Location of Leak 4 Front of Vehicle

4 T-SB November 3, 2008 Page 4 of 5 Repair Procedure (Continued) B. Is red fluid leaking from the transfer case breather plug (vent) on top of the front side of the transfer case? Figure 2. If YES This TSB applies Go to step 2. If NO to question 1A and 1B, then this TSB does NOT apply. Continue diagnosis to determine root cause of fluid leak. 1 Transfer Case Breather Plug (Vent) 2. Check the transfer case fluid level. Figure 3. Refer to the Technical Information System (TIS), applicable model and model year Repair Manual: 2008 Highlander, Drivetrain Transfer 4WD/Awd MF2A Transfer: Transfer Oil: On-Vehicle Inspection 2008 or 2009 Sienna, Drivetrain Transfer/4WD/Awd Transfer: Transfer Oil: On Vehicle Inspection Also refer to Figure 3 to assist in identifying the transfer plug No. 1. Confirm that transfer case fluid (gear oil) is overfilled or appears to be contaminated with ATF prior to going to next step. 1 No. 2 Plug 2 No. 1 Plug 3 Drain Plug

5 T-SB November 3, 2008 Page 5 of 5 Repair Procedure (Continued) 3. Replace the transfer case assembly. For Highlander, refer to TIS, 2008 model year Repair Manual: Highlander, Drivetrain Transfer 4WD/Awd MF2A Transfer: Transfer Assembly: For Sienna, refer to TIS, applicable model year Repair Manual: Sienna, Drivetrain Transfer/4WD/Awd Transfer: Transfer Assembly: 2009 Sienna, Drivetrain Transfer/4WD/Awd Transfer: Transfer Assembly: 4. Check ATF level in automatic transaxle and confirm level is correct. Adjust as needed. 5. Test drive vehicle and confirm there is NO leak from the transfer case.

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