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Autopapyrus · Toyota Hi-ace H200 3.0 diesel 1KD-FTV (2014)
https://autopapyrus.com/guides/toyota/hi-ace/transfer-case-oil-change/
Compiled automatically from service literature and owner experience. Specs are for the typical configuration — check them against your exact car before you start.

Toyota Hi-ace H200 3.0 diesel 1KD-FTV (2014): Transfer Case Oil Change

The transfer case on 4WD Hi-ace H200 vans needs an oil change every 40,000-60,000 km or whenever the transmission is serviced. The manufacturer recommended GL-3 85W-90, but that grade has been discontinued, so a modern GL-4/GL-5 75W-90 is used instead. The procedure is simple, but access to the plugs is limited, so you will need a pit or a lift.

Difficulty: Medium Time: 30-40 minutes Steps: 10 Tools: 24 mm socket, extension, ratchet, torque wrench, drain pan (2 L (2.1 qt)), gear oil filler syringe with flexible hose or a dedicated pump

Part

  • 🔩 Gear oil 75W-90 API GL-4/GL-5, 1.3 L (1.4 qt) (Castrol TAF-X, Motul Gear 300, Shell Spirax or equivalent). Copper washers for the drain and fill plugs (90430-18008 or equivalent), 2 pcs

Step by step

10 steps
  1. Warm up the transfer case by driving for 10-15 minutes in 4WD mode, so the oil thins out and drains more completely.
  2. Park the vehicle on a level, horizontal surface (pit or lift) and secure it with the parking brake.
  3. Locate the transfer case under the vehicle, between the transmission and the rear driveshaft. The housing has two 24 mm plugs (the upper one is the fill plug, the lower one is the drain plug).
  4. FIRST remove the fill plug (upper). If it will not come loose, do not drain the oil, or you will not be able to refill the case with new oil.
  5. Place the drain pan underneath and remove the drain plug (lower). The oil will come out in a dark stream. Let it drain for 5-7 minutes.
  6. Inspect the drained oil for metal shavings or water. If there is metallic sludge, the transfer case needs to be diagnosed.
  7. Clean the old washer and dirt off the drain plug, fit a new copper washer, thread the plug in and tighten it to 36-40 N·m (27 lb-ft).
  8. Through the fill hole, pour in fresh 75W-90 oil with a syringe and flexible hose. Keep filling until oil begins to run out of the fill hole (about 1.3 L (1.4 qt)).
  9. Let the oil settle to the level of the hole's lower edge, fit a new washer on the fill plug, thread it in and tighten it to 36-40 N·m (27 lb-ft).
  10. Wipe any oil residue off the transfer case housing, lower the vehicle, drive 5 km, and check the plugs for leaks.

Common mistakes and warnings

  • Do not overtighten the plugs. The threads in the aluminum transfer case housing can strip. Always replace the copper washers at every oil change, because reusing old ones leads to leaks. If you find traces of oil on the transfer case housing under the vehicle, check the axle shaft seals and the driveshaft seal, as a leak may indicate worn seals.
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