Toyota FJ Cruiser (GSJ 10, 15 series). Instruction — part 427
MT–54
RA61F MANUAL TRANSMISSION – INPUT SHAFT
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14. INSTALL GEAR THRUST WASHER SHAFT SNAP
RING
(a) Select a snap ring that will allow minimum axial play.
Standard clearance:
0.1 mm (0.004 in.) or less
Snap ring thickness
(b) Using a snap ring expander, install the snap ring
onto the input shaft.
15. INSTALL SHAFT SNAP RING
(a) Coat the shaft snap ring with gear oil, and install it
onto the input shaft.
16. INSTALL 6TH GEAR NEEDLE ROLLER BEARING
(a) Coat the 6th gear needle roller bearing with gear oil,
and install it onto the input shaft.
D033654E01
Part No.
Thickness: mm (in.)
Mark
90520-39026
2.07 to 2.12
(0.0815 to 0.0835)
A
90520-39027
2.12 to 2.17
(0.0835 to 0.0854)
B
90520-39028
2.17 to 2.22
(0.0854 to 0.0874)
C
90520-39029
2.22 to 2.27
(0.0874 to 0.0894)
D
90520-39030
2.27 to 2.32
(0.0894 to 0.0913)
E
90520-39031
2.32 to 2.37
(0.0913 to 0.0933)
F
F051088E01
F051087E01
RA61F MANUAL TRANSMISSION – INPUT SHAFT
MT–55
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17. INSTALL 6TH GEAR
(a) Install the 6th gear onto the input shaft.
(b) Install the synchronizer ring onto the input shaft.
(c) Using SST and a press, install the clutch hub onto
the input shaft.
SST
09309-37010, 09950-00020
(d) Install the clutch hub and confirm that the gear and
synchronizer ring move smoothly.
18. INSTALL TRANSMISSION CLUTCH HUB NO.3 SHAFT
SNAP RING
(a) Select a snap ring that will allow minimum axial play.
Standard clearance:
0.1 mm (0.004 in.) or less
Snap ring thickness
(b) Using a brass bar and a hammer, install the snap
ring onto the input shaft.
SST
SST
F051619E01
F051105E01
Part No.
Thickness: mm (in.)
Mark
90520-33022
2.10 to 2.15
(0.0827 to 0.0847)
A
90520-33023
2.15 to 2.20
(0.0847 to 0.0866)
B
90520-33024
2.20 to 2.25
(0.0866 to 0.0886)
C
90520-33025
2.25 to 2.30
(0.0886 to 0.0906)
D
90520-33026
2.30 to 2.35
(0.0906 to 0.0925)
E
90520-33027
2.35 to 2.40
(0.0925 to 0.0945)
F
90520-33028
2.40 to 2.45
(0.0945 to 0.0965)
G
MT–56
RA61F MANUAL TRANSMISSION – INPUT SHAFT
MT
19. INSPECT 6TH GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 6th gear thrust
clearance.
Standard clearance:
0.20 to 0.49 mm (0.0079 to 0.0193 in.)
If the clearance is outside the specification, replace
the defective gear, spacer or shaft.
20. INSPECT 3RD GEAR THRUST CLEARANCE
(a) Using a feeler gauge, measure the 3rd gear thrust
clearance.
Standard clearance:
0.09 to 0.52 mm (0.0035 to 0.0205 in.)
If the clearance is outside the specification, replace
the defective gear, thrust washer, clutch hub or
shaft.
21. INSPECT 4TH GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 4th gear thrust
clearance.
Standard clearance:
0.12 to 0.38 mm (0.0047 to 0.0150 in.)
If the clearance is outside the specification, replace
the defective gear, clutch hub or shaft.
22. INSPECT 6TH GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 6th gear radial
clearance.
Standard clearance:
0.015 to 0.065 mm (0.0006 to 0.0026 in.)
If the clearance is outside the specification, replace
the defective gear, needle roller bearing or shaft.
23. INSPECT 3RD GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 3rd gear radial
clearance.
Standard clearance:
0.015 to 0.067 mm (0.0006 to 0.0026 in.)
If the clearance is outside the specification, replace
the defective gear, needle roller bearing or shaft.
F051109E01
F051110E01
F051111E01
F051106E01
F051107E01
RA61F MANUAL TRANSMISSION – INPUT SHAFT
MT–57
MT
24. INSPECT 4TH GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 4th gear radial
clearance.
Standard clearance:
0.015 to 0.067 mm (0.0006 to 0.0026 in.)
If the clearance is outside the specification, replace
the defective gear, needle roller bearing or shaft.
F051108E01
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