Toyota FJ Cruiser (GSJ 10, 15 series). Manual — part 422
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RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
MT
16. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY
(a) Using SST, install the back-up light switch with a
new gasket onto the transmission front case.
SST
09817-16011
Torque: 44 N*m (449 kgf*cm, 33 ft.*lbf)
17. INSTALL SHIFT AND SELECT LEVER CAM
(a) Install the shift and select lever cam onto the shaft
and install a new E-ring.
18. INSTALL SHIFT AND SELECT LEVER
(a) Install the lock ball pin and spring onto the shift and
select lever.
(b) Install the shift and select lever onto the shift and
select lever cam and shaft.
(c) Install the bolt onto the shift and select lever.
Torque: 33 N*m (340 kgf*cm, 25 ft.*lbf)
19. INSTALL SHIFT AND SELECT LEVER SHAFT
(a) Align the groove of the shift and select cam with the
reverse idler shaft, and the claw with the groove of
the control assembly, and install them.
20. INSTALL NO. 2 OIL RECEIVER PIPE
(a) Install the No. 2 oil receiver pipe into the
transmission middle case.
SST
F051581E01
F051580
F051579
D033647
F051577
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
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21. INSTALL DRAIN PLUG SUB-ASSEMBLY
(a) Install the drain plug with a new gasket onto the
transmission middle case.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
22. INSTALL TRANSMISSION MIDDLE CASE
(a) Apply FIPG to the transmission middle case, as
shown in the illustration.
FIPG:
Toyota Genuine Seal Packing 1281, Three
Bond 1281 or Equivalent
NOTICE:
Parts must be assembled within 10 minutes of
the application. Otherwise, the packing (FIPG)
material must be removed and reapplied.
(b) Install the transmission middle case with the 11 bolts
onto the transmission front case.
Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
Bolt length:
Bolt A: 40 mm (1.57 in.)
Bolt B: 80 mm (3.15 in.)
23. INSTALL REVERSE IDLER GEAR SHAFT BOLT
(a) Install a new gasket and the reverse idler gear shaft
bolt onto the reverse idler gear shaft.
Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
24. INSTALL TRANSMISSION OIL SEPARATOR
(a) Install the transmission oil separator with the 2 bolts.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
F051576
FIPG
D033756E01
D033740
D033649
F051575
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RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
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25. INSTALL COUNTER GEAR REAR RADIAL BALL
BEARING
(a) Coat a new counter gear rear radial ball bearing
with gear oil, and using SST and a press, install it
into the transmission rear case.
SST
09950-70010 (09951-07360), 09950-60010
(09951-00650)
(b) Install the bearing lock plate with the bolt.
Torque: 11 N*m (115 kgf*cm, 8.3 ft.*lbf)
26. INSTALL OUTPUT SHAFT REAR BEARING OUTER
RACE
(a) Using SST and a press, press in 2 new bearing
outer races.
SST
09950-70010 (09951-07100, 09951-07360),
09950-60020 (09951-00790)
27. INSTALL OIL SEPARATOR PACKING SEAL
(a) Install the oil separator packing seal onto the
transmission rear case.
HINT:
Insert the protruding part of the oil separator
packing seal into the groove on the transmission
rear case.
28. INSTALL EXTENSION HOUSING OIL RECEIVER PIPE
(a) Install the extension housing oil receiver pipe onto
the transmission rear case.
SST
D033750E01
D033746
SST
SST
D033749E01
D033752
F051573
RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
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MT
29. INSTALL MANUAL TRANSMISSION FILLER PLUG
(a) Install the 2 transmission filler plugs with 2 new
gaskets onto the transmission rear case.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
30. INSTALL TRANSMISSION REAR CASE
(a) Apply FIPG to the transmission rear case, as shown
in the illustration.
FIPG:
Toyota Genuine Seal Packing 1281, Three
Bond 1281 or Equivalent
NOTICE:
Parts must be assembled within 10 minutes of
the application. Otherwise, the packing (FIPG)
material must be removed and reapplied.
(b) Install the transmission rear case with the 10 bolts
and 3 brackets onto the transmission middle case.
Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
31. INSTALL SHIFT DETENT BALL PLUG
(a) Install the ball and compression spring onto the
transmission rear case.
(b) Install a new shift detent ball plug, and install it onto
the transmission rear case.
Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)
32. INSTALL OUTPUT SHAFT ADJUST NUT
(a) Using a belt and wooden block, fasten the
transmission to the workbench.
(b) Install a new spacer and output shaft taper roller
bearing No. 2.
F051572
FIPG
D033757E01
Clamp
Clamp
D033738E01
F051570
D033736
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