Front Differential / Transfer Case Leak

RJSHighlander · Jan 24, 2015

Hi

First quick question, is the front differential the same as the transfer case on this car? There appears to be some confusion on this.

So, my real question/ issue is this. Our 2008 Highlander was in to the dealer for its 85K mile service in October. They mentioned the front differential had a very small fluid leak. They topped-up the fluid and said leave it until the 90K service when they would check it again. Oh, and they quoted me $1,800 to reseal the differential! Said it was a tranny out, two day job! Yikes!

I had the 90K mile service this week and same report.

So, I am wondering a few things:
-Is this a known issue for this car? Is there a TSB on this?
-If so, where exactly is it leaking from?
-Are there other options to remedy this? A tranny-out service to reseal it seems extreme before exploring other options first (i.e. could it be as simple as re-torquing a few of the case bolts, or am I being naive?).
-What guarantee do I have it won't leak again?
-If the leak is this small, is there any risk to simply topping-up the fluid every 5K miles (I am happy to check the fluid myself every few weeks to monitor the severity of the leak).
-Should I get a second opinion on repair options from an independent garage?

I visually checked the outside of the front differential myself this morning. It does appear damp but, it is certainly not wet. So, I am comfortable the leak is not bad.

Thanks

Bob
PS: I bought this Toyota for my wife due to Toyota's reliability and low maintenance costs. Yet, I've owned Volvos and BMWs for well over 100K miles and never had an issue like this. Pretty disappointed.....

sweeneyp · Jan 25, 2015

The front and center differential are built into the transaxle, so any work on those require the transaxle to be dropped unfortunately.

There are 2 leak related TSB's for 08's:
T-SB-0335-08 (ATF Leak from Transfer Case)

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

T-SB-0031-11 (Gear Oil Leak from Front Propeller Shaft Yoke)

Some 2008 – 2011 model year Highlander 4WD vehicles may exhibit a gear oil leak from the front yoke of the propeller shaft assembly. The manufacturing process for the front propeller shaft yoke has been modified to address this condition. Please follow the repair procedure to replace the propeller shaft assembly.

Unfortunately that's where my knowledge on this ends. I haven't heard this come up on the forum yet. If its slow enough, occasionally topping off isn't a bad idea vs heavy $$$.

nov0798 · Jan 26, 2015

I had the same problem . I noticed mine at about 65k, and they fixed it for free. The parts were like 17.00, and the labor was close to 1700. Its alot of work to get that thing in and out.

DeliciousBlonde1020 · Feb 8, 2021

I’m having the same problem, same vehicle, nov0798 how did you get it fixed for free? The mechanic I just took it to and have been taking the Highlander to for services and maintenance quoted me around $2,000 he stated 20 hours of labor! Omg! If Toyota knows about this anc it’s a common problem and it’s caused by some fault of theirs wouldn’t it be a recall and fixed by a dealer for free? I just don’t understand or even an authorized partner of Toyota could still fix it as a recall repair it’s just extra paperwork for them and work for nothing or barely anything ! Can someone please explain to me why it takes so long to repair this and why it’s not a recall repair? Thank you!

underthehood51 · Feb 8, 2021

Recall repairs pretty much only involve safety issues. Check with your dealer. There may be an extended warranty or courtesy warranty. I don't think it's a "common" issue. Seals can and will fail occasionally but reading about 1 or 2 hardly constitutes some huge warranty campaign. Not discounting your trouble here but, I doubt this is an issue any more common than with any other type of seal on a spinning shaft

Front Differential / Transfer Case Leak

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