I dropped the FJ at Iron Pig last Sunday, due to what looks like a pretty serious leak in the new inchworm transfer case. I was trying to trace the cause of the non-working A-TRAC system and was very surprised when I poked my head under the truck and found a very dirty transfer case and actual oil drops on the bottom surfaces (you can actually see the drops in the picture). There is no indication of any problems driving the truck (it made the 150 miles or so to IP with no trouble) and there was no oil leakage on my driveway, where the FJ had been sitting for two weeks before the trip to the shop.
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Any updates on the diagnosis or repair?
My post-trip repairs consisted of an alignment, tightening the skid plates (bad vibration sound only with in reverse- didn't know skid plates could do that), and a full detail. The FJ is now good as new.
Diagnosis was a failure on the transfer case seal somewhere around the forward output shaft (a bolt not fully torqued, it seems). Terry @ IPOR is trying to reach Inchworm to have them cover the repairs, since this was due to improper assembly of the unit.
Turns out the ATRAC was disabled because the system requires two sensor switches for 4wd selection, and only one switch point exists on the lefty. IPOR is going to drive both switches from the single available sensor, and that should fix it.
Good news on your repairs bill! And yeah, skid plates do that -- mine vibrate on reverse even when they are tight!
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