Okay I just replaced the transfer case fluid yesterday. Lots of dark gunky fluid out, nice clean Amsoil Severe Gear in. Let's see if that makes any difference in gas mileage
I bought a 24mm wrench, and it was pretty loose on the drain plug. I think 15/16" would have been better. I could not fit the box end of the wrench on that plug -- had to use the open end. not much room around that bolt head!
I used a 15/16" socket for the fill plug, which worked nicely with almost no play. So I would vote that these bolts are 15/16" ... where was the transfer case made?
*** UPDATE: The Lexus forums I checked also said 15/16" ... a buddy's 2000 RX300 looks like it has the same diff and xfer case as my Sienna. ***
Those contoured crush washers are pretty cool. They put up moderate resistance until you bottom them out, then it gets real hard, a couple of solid tugs to crank the bolt just a tad more, then you're done. (Torque wrench not usable on the drain plug, but I've got a good feel for 30-40 ft-lbs nowadays).