Transfer Case  &

differential

oil changes

The transfer case and front/rear differential oils in the LandCruiser 200 should be changed at 40,000km intervals. More frequently if you're operating in severe conditions.

The local dealer will charge you a whopping $400 to change these oils, but it's one of the simplest service procedures you'll ever find, and you can do it yourself in under an hour with basic tools and less than $200 worth of premium quality oil.

Differential oil

The LandCruiser 200 in Australia runs 'open'  differentials front and rear, so there's no requirement to use limited slip oil in the rear diff. Between the front and rear differentials, a total of approximately 6.3 litres of oil is required.

The specified oil is a 75W85 viscosity, with a GL-5 specification. The GL-5 spec is quite high, and generally means you'll have to select a fully synthetic oil. Most 75W85 gear oils are mineral or semi-synthetic, and only meet the GL-4 specification. There are very few oils available that meet the required specifications. The following are suitable:

 

Penrite Pro Gear GL-5 75W85:  Progear GL5 is a fully synthetic gearbox and differential oil from Australian company Penrite. Note that Penrite make GL-4 and GL-5 versions of ProGear 75W85. You MUST use the GL-5 version in the 200's differentials. It's available in 1, 2.5, 4 and 20 litre containers:

Redline gear oil 75W85:  Redline is a specialised US oil manufacturer. They produce a suitable fully-synthetic GL-5 oil which comes in US sizes of 1 quart (946ml)  and 1 gallon (3.79L).

Transfer case oil

The recommended oil for the transfer case in the 200 is slightly different to the differentials, being a 75W90 GL-5 gear oil. Only around 1.5 litres of oil is required for a full change.

There are a few more choices in this grade, with the following being suitable:

 

Penrite Pro Gear 75W90:  Progear 75W90 is a fully synthetic gearbox and differential oil from Australian company Penrite. It's available in 1, 2.5 and 4 litre containers:

Redline 75W90 GL-5:  Redline produce a suitable fully-synthetic GL-5 oil which comes in US sizes of 1 quart (946ml)  and 1 gallon (3.79L). Note that Redline make GL-4 and GL-5 versions of 75W90 oil. You MUST use the GL-5 version in the 200's transfer case.

Amsoil Severe Gear 75W90:  This is a fully synthetic gear oil from US manufacturer Amsoil. It comes in US sizes of 1 quart (946ml)  and 1 gallon (3.79L).

Castrol Syntrax Universal Plus 75W90:  Syntax Universal Plus is a fully synthetic, GL-5 gear oil. It's available in 1, 2.5, 4 and 20 litre containers.

Nulon Smooth Shift 75W90:  This is a fully-synthetic GL-5 gear oil from Australian company Nulon. It's available in 1, 2.5 and 4 litre containers.

Nulon Smooth Shift 75W90:  This is a fully-synthetic GL-5 gear oil from Australian company Nulon. It's available in 1, 2.5 and 4 litre containers.

IMPORTANT

The following should not be taken as instructions. It is simply a documenting of the procedure I followed for my own servicing and maintenance. No warranty is provided as to the accuracy of the information, and/or whether it applies in your situation or to your vehicle.

There are many additional checks which take place during routine vehicle servicing. It's not just a 'grease and oil change'. You may not be aware of these checks, which could lead to component failures. I strongly recommend you have your vehicle serviced regularly by a qualified mechanic. If you're not qualified and/or don't have the correct equipment, don't attempt to perform your own vehicle maintenance.

  • There are potentially lethal dangers resulting from the vehicle during the procedure.
  • There are potentially lethal dangers resulting from component failures which would ordinarily be checked during routine servicing.
  • There is the potential for expensive vehicle damage from improper servicing procedures.

If you undertake your own servicing, you do so entirely at your own risk.

Parts and Equipment required - Diff and Transfer oil change

Rear Differential oil change

Click images to enlarge

Step 1: Drain the oil

  • Place a drain pan (at least 5 litres capacity) under the differential
  • Remove the fill plug and the drain plug, using a 24mm socket.
  • Allow the oil to completely drain out.

Step 2: Refill the differential

  • Clean the fill and drain plugs, including the magnet on the drain plug. Note: Expect the drain plug to have some metallic sludge stuck to the magnet. This is normal. However, any large filings or chunks of metal would indicate damage inside the differential, and require further investigation.
  • Fit new crush washers to the fill and drain plugs
  • Refit the drain plug and tension to 49Nm.
  • Refill the differential with 75W85 GL5-spec oil, until the oil flows from the fill hole. Capacity is around 4.2 litres.
  • Replace the fill plug and tension to 49Nm.

Front Differential oil change

Step 1: Preparation and oil drain

  • Remove the bash plate/cover under the differential;
  • Place a drain pan (at least 3 litres capacity) under the differential;
  • Using a 10mm allen wrench, remove the fill and drain plugs;
  • Allow the oil to fully drain out.

If you have the standard plastic cover/plate, then these are the bolts to remove:

Step 2: Refill the differential

  • Clean the fill and drain plugs, including the magnet on the drain plug. Note: Expect the drain plug to have some metallic sludge stuck to the magnet. This is normal. However, any large filings or chunks of metal would indicate damage inside the differential, and require further investigation.
  • Fit a new copper washer to the drain plug and a new crush washer to the fill plug;
  • Refit the drain plug and tension to 39Nm;
  • Refill the differential with 75W85 GL5-spec oil, until the oil flows from the fill hole. Capacity is around 1.9 litres;
  • Replace the fill plug and tension to 39Nm;
  • Replace the bash plate/cover under the differential.

Transfer Case oil change

Step 1: Preparation and oil drain

  • Using a 14mm spanner or socket, remove the vibration dampener from the rear of the transfer case;
  • Remove the clip holding the earth strap from the transfer case guard. Pushing the small plastic tab on the rear of the clip will allow you to pull it upwards off the bracket.
  • Using a 12mm spanner and socket, remove the 8 bolts holding the guard to the transfer case;
  • Remove the fill and drain plugs, and allow all the oil to drain out.

Step 2: Refill the transfer case

  • Fit new aluminium washers to the drain and fill plugs;
  • Refit the drain plug and tension to 37Nm;
  • Refill the differential with 75W90 GL5-spec oil, until the oil flows from the fill hole. Capacity is around 1.5 litres;
  • Replace the fill plug and tension to 37Nm.

Step 3: Refit the guard and dampener

  • Replace the transfer case guard;
  • Apply loctite to the guard retaining bolts and replace the bolts;
  • Re-attach the earth strap clip;
  • Re-attach the dampener.
14000kg soft shackle

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