Toyota FJ Cruiser (GSJ 10, 15 series). Manual — part 425

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RA61F MANUAL TRANSMISSION – INPUT SHAFT

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21. REMOVE INPUT SHAFT FRONT BEARING SNAP

RING
(a) Using 2 screwdrivers and a hammer, tap out the

snap ring.
HINT:
Use a shop rag or piece of cloth to prevent the snap
ring from flying off.

22. REMOVE INPUT SHAFT FRONT BEARING

(a) Using SST and a press, remove the input shaft front

bearing from the input shaft.
SST

09950-00020

NOTICE:
Support the input shaft by hand so that it does
not fall off.

23. REMOVE NO. 2 TRANSMISSION CLUTCH HUB

(a) Remove the clutch hub, 3 synchromesh shifting

keys, 3 balls and 3 springs from the hub sleeve.
HINT:
Use a shop rag or piece of cloth to prevent the ball
and spring from flying off.

24. REMOVE NO. 3 TRANSMISSION CLUTCH HUB

(a) Perform the same procedures as for the No. 2

clutch hub.

INSPECTION

1.

INSPECT INPUT SHAFT
(a) Using a dial indicator and 2 V-blocks, measure the

shaft runout.
Maximum runout:

0.03 mm (0.0012 in.)

If the runout exceeds the maximum, replace the
input shaft.

D033659E01

SST

D033660E01

Ball

Spring

Synchromesh
Shifting Key

C136406E01

F051113E01

RA61F MANUAL TRANSMISSION – INPUT SHAFT

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(b) Using a micrometer, measure the outer diameters of

the input shaft journal surface, at the specified
positions.
Standard

Minimum

If any of the outer diameters are less than the
minimum, replace the input shaft.

2.

INSPECT 6TH GEAR
(a) Using a cylinder gauge, measure the inside

diameter of the 6th gear.
Standard inside diameter:

51.015 to 51.040 mm (2.0085 to 2.0095 in.)

Maximum inside diameter:

51.040 mm (2.0095 in.)

If the inside diameter exceeds the maximum,
replace the 4th gear.

3.

INSPECT 3RD GEAR
(a) Using a cylinder gauge, measure the inside

diameter of the 3rd gear.
Standard inside diameter:

51.015 to 51.040 mm (2.0085 to 2.0095 in.)

Maximum inside diameter:

51.040 mm (2.0095 in.)

If the inside diameter exceeds the maximum,
replace the 3rd gear.

4.

INSPECT 4TH GEAR
(a) Using a cylinder gauge, measure the inside

diameter of the 4th gear.
Standard inside diameter:

51.015 to 51.040 mm (2.0085 to 2.0095 in.)

Maximum inside diameter:

51.040 mm (2.0095 in.)

If the inside diameter exceeds the maximum,
replace the 4th gear.

A

B

C

D

E

D033763E01

Part

Outer diameter mm (in.)

A

34.002 to 34.015 (1.3387 to 1.3392)

B

44.985 to 45.000 (1.7711 to 1.7717)

C

44.985 to 45.000 (1.7711 to 1.7717)

D

41.985 to 42.000 (1.6530 to 1.6535)

E

32.967 to 32.974 (1.2979 to 1.2982)

Part

Outer diameter mm (in.)

A

34.002 (1.3387)

B

44.985 (1.7711)

C

44.985 (1.7711)

D

41.985 (1.6530)

E

32.967 (1.2979)

F051115E01

F051116E01

F051117E01

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RA61F MANUAL TRANSMISSION – INPUT SHAFT

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5.

INSPECT NO. 2 TRANSMISSION HUB SLEEVE
(a) Check the sliding condition between the No. 2

transmission hub and No. 2 transmission hub
sleeve.

(b) Check that the spline gear teeth of the No. 2

transmission hub sleeve are not worn.

(c) Using vernier calipers, measure the width of the No.

2 transmission hub sleeve groove (A) and the
thickness of the claw part on the No. 2 or No. 3 gear
shift forks (B), and calculate the clearance.
Standard clearance:

(A - B);
0.28 to 0.84 mm (0.0110 to 0.0331 in.) for No. 2
gear shift fork
0.28 to 0.65 mm (0.0110 to 0.0256 in.) for No. 3
gear shift fork

If the clearance is outside the specification, replace
the No. 2 transmission hub sleeve and gear shift
fork.

6.

INSPECT NO. 3 SYNCHRONIZER RING (FOR 6TH
GEAR)
(a) Using a feeler gauge, measure the clearance

between the synchronizer ring and the 6th gear.
Standard clearance:

0.70 to 1.50 mm (0.0276 to 0.0591 in.)

Minimum clearance:

0.70 mm (0.0276 in.)

If the clearance is less than the minimum, replace
the synchronizer ring.

(b) Coat the 6th gear cone with gear oil. Check the

braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to
the 6th gear cone. Check that the ring locks.

C067843E01

B

A

F051119E01

F051611E01

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RA61F MANUAL TRANSMISSION – INPUT SHAFT

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7.

INSPECT NO. 2 SYNCHRONIZER RING SET (FOR
3RD GEAR)
(a) Using a feeler gauge, measure the clearance

between the synchronizer ring and the 3rd gear.
Standard clearance:

Inner:

1.20 to 2.20 mm (0.0472 to 0.0866 in.)

Middle:

0.60 to 1.80 mm (0.0236 to 0.0709 in.)

Outer:

0.80 to 1.80 mm (0.0315 to 0.0709 in.)

Minimum clearance:

Inner:

1.20 mm (0.0472 in.)

Middle:

0.60 mm (0.0236 in.)

Outer:

0.80 mm (0.0315 in.)

If the clearance is less than the minimum, replace
the synchronizer ring.

(b) Coat the 3rd gear cone with gear oil. Check the

braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to
the 3rd gear cone. Check that the ring locks.

8.

INSPECT NO. 3 SYNCHRONIZER RING (FOR 4TH
GEAR)
(a) Using a feeler gauge, measure the clearance

between the synchronizer ring and 4th gear.
Standard clearance:

0.70 to 1.50 mm (0.0276 to 0.0591 in.)

Minimum clearance:

0.70 mm (0.0276 in.)

If the clearance is less than the minimum, replace
the synchronizer ring.

(b) Coat the 4th gear cone with gear oil. Check the

braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to
the 4th gear cone. Check that the ring locks.

F051613E01

F051614E01

F051611E01

F051612E01