Leaking Transfer Case Is Shot

[Silversport01]

I started hearing bearing noise about 3 months ago, went to dealer for 90,000 mi service and it turns out my transfer case leaked all the fluid out and was toast.

Rather than pay the $5000 for the new unit I went to a local transmission shop that was recommended to me by an independant Lexus shop. They tore the thing apart and quoted me $2300 for a rebuild, no problem.

After 2 months of having supposed back order issues, that turned out to just be that they weren't looking in the right section of their parts book and the local toyota dealer they were talking to was no help, they finished the rebuild. It leaked all the fluid out within 2 days and was back in the shop.

Now 2 weeks later they finished the second rebuild, guess what... still leaking!!! Now they're saying that the case must be cracked and are looking for another transfer case to rebuild. I haven't had my car for 3 months and it's affected work and my home life, if I could afford to just take it back and go to the dealership for a new unit I would, but I can't and am now stuck in this cycle of rebuilds.

:cries:

Any ideas on what else I can do?

[code58]

I started hearing bearing noise about 3 months ago, went to dealer for 90,000 mi service and it turns out my transfer case leaked all the fluid out and was toast.

Rather than pay the $5000 for the new unit I went to a local transmission shop that was recommended to me by an independant Lexus shop. They tore the thing apart and quoted me $2300 for a rebuild, no problem.

After 2 months of having supposed back order issues, that turned out to just be that they weren't looking in the right section of their parts book and the local toyota dealer they were talking to was no help, they finished the rebuild. It leaked all the fluid out within 2 days and was back in the shop.

Now 2 weeks later they finished the second rebuild, guess what... still leaking!!! Now they're saying that the case must be cracked and are looking for another transfer case to rebuild. I haven't had my car for 3 months and it's affected work and my home life, if I could afford to just take it back and go to the dealership for a new unit I would, but I can't and am now stuck in this cycle of rebuilds.

:cries:

Any ideas on what else I can do?

"Case must be cracked"? This is a trans. shop that was recommended by an independent Lexus shop? I can't believe that they are guessing the case must be cracked. I would think any competent tranny guy should be able to TELL if it was cracked or not. Good Luck- looks like you're between a rock and a hard place- at least you know where not to go back to for any future tranny work.

[Silversport01]

UPDATE:

3rd rebuild with new donor case appeared to fix the issue, but after about 1.5 months i started smelling the burning diff fluid on exhaust smell again.

Took it back in and the shop said the fluid level looked good but there was some fluid seeping out of the slip yoke itself, and that it should be replaced.

Is this even possible?

I would think that the yoke is "dry" and that the tailshaft would have a seal to the transfer case not allowing fluid to get to the yoke?

If this is not the case, what keeps a "good" yoke from leaking, is there some kind of o ring on the tailshaft?

help?

Thx

I started hearing bearing noise about 3 months ago, went to dealer for 90,000 mi service and it turns out my transfer case leaked all the fluid out and was toast.

Rather than pay the $5000 for the new unit I went to a local transmission shop that was recommended to me by an independant Lexus shop. They tore the thing apart and quoted me $2300 for a rebuild, no problem.

After 2 months of having supposed back order issues, that turned out to just be that they weren't looking in the right section of their parts book and the local toyota dealer they were talking to was no help, they finished the rebuild. It leaked all the fluid out within 2 days and was back in the shop.

Now 2 weeks later they finished the second rebuild, guess what... still leaking!!! Now they're saying that the case must be cracked and are looking for another transfer case to rebuild. I haven't had my car for 3 months and it's affected work and my home life, if I could afford to just take it back and go to the dealership for a new unit I would, but I can't and am now stuck in this cycle of rebuilds.

:cries:

Any ideas on what else I can do?

"Case must be cracked"? This is a trans. shop that was recommended by an independent Lexus shop? I can't believe that they are guessing the case must be cracked. I would think any competent tranny guy should be able to TELL if it was cracked or not. Good Luck- looks like you're between a rock and a hard place- at least you know where not to go back to for any future tranny work.

[blk_on_blk]

Since I have a 2WD, I'm not familiar with the transfer case, but I can say I've had transmission issues and the shop I brought it to, Todd's Import Automotive over in Lake-O, has been great with the diagnosis and repair. Instead of trying to have someone local do a rebuild, they work with Howard Engineering Corp who specializes in rebuilt engines and transmissions, http://www.hecreman.com/ , to do a straight transmission swap...I'm guessing they probably do the transfer cases, too. Either way, these guys are specialists in what they do, and they offer a nice 3-year/30,000 mile warranty on their trannies/power-train components.

If you are at the end of your rope in dealing with the dealer and/or your shop, Todd's Import Automotive is a good alternative. We take both our Lexus's there and with an array of strange things showing up on our vehicles, Todd's crew has been great to work with. ...it's just an option.

[Silversport01]

The shop I'm going through said that they could not find anyone remanufacturing the RX transfercase, I'll check and see if Todd's can source any.

I've had people recommend Todd's after I had already gotten into this mess, and in the future I'm going to try them, thanks for the referral.

Anyone else have any thoughts on the bad yoke theory?