Toyota FJ Cruiser (GSJ 10, 15 series). Instruction — part 426
MT–50
RA61F MANUAL TRANSMISSION – INPUT SHAFT
MT
9.
INSPECT 3RD GEAR THRUST WASHER
(a) Using a micrometer, measure the thrust washer
thickness.
Standard thickness:
7.12 to 7.18 mm (0.2803 to 0.2827 in.)
Minimum thickness:
7.12 mm (0.2803 in.)
If the thickness is less than the minimum, replace
the thrust washer.
REASSEMBLY
1.
INSTALL INPUT SHAFT FRONT BEARING
(a) Using SST and a press, install the input shaft front
bearing onto the input shaft.
SST
09950-00020
HINT:
Make sure that the groove of the bearing faces the
correct direction as shown in the illustration.
2.
INSTALL INPUT SHAFT FRONT BEARING 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 hammer, install the snap ring
onto the input shaft.
F051615E01
SST
D033669E01
F051102E01
Part No.
Thickness: mm (in.)
Mark
90520-31026
2.65 to 2.70
(0.1043 to 0.1063)
A
90520-31027
2.70 to 2.75
(0.1063 to 0.1083)
B
90520-31028
2.75 to 2.80
(0.1083 to 0.1102)
C
90520-31029
2.80 to 2.85
(0.1102 to 0.1122)
D
90520-31030
2.85 to 2.90
(0.1122 to 0.1142)
E
90520-31031
2.90 to 2.95
(0.1142 to 0.1161)
F
RA61F MANUAL TRANSMISSION – INPUT SHAFT
MT–51
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3.
INSTALL NO. 2 TRANSMISSION CLUTCH HUB
(a) Apply a light coat of gear oil to the sleeve and hub.
(b) Install the clutch hub sleeve onto the No. 2 clutch
hub.
(c) Put the ball into the keyhole from the bottom.(*1)
(d) Put the spring under the ball.(*2)
(e) Insert the ball and spring into the No. 2 clutch hub
while attached onto the key.(*3)
NOTICE:
Prevent the ball from flying off.
HINT:
•
Perform the same procedure (*1 through *3) for
all the 3 portions.
•
Make sure that the No. 2 clutch hub faces the
correct direction as shown in the illustration.
4.
INSTALL NO. 3 TRANSMISSION CLUTCH HUB
(a) Apply a light coat of gear oil to the sleeve and hub.
(b) Install the clutch hub sleeve onto the No. 3 clutch
hub.
(c) Put the ball into the keyhole from the bottom.(*1)
(d) Put the spring under the ball.(*2)
(e) Insert the ball and spring into the No. 3 clutch hub
while attached onto the key.(*3)
NOTICE:
Prevent the ball from flying off.
HINT:
•
Perform the same procedure (*1 through *3) for
all the 3 portions.
•
Make sure that the No. 3 clutch hub faces the
correct direction as shown in the illustration.
5.
INSTALL 4TH GEAR NEEDLE ROLLER BEARING
(a) Coat the 4th gear needle roller bearing with gear oil,
then install it onto the input shaft.
6.
INSTALL 4TH GEAR
(a) Coat the 4th gear and No. 3 synchronizer ring with
gear oil, then install them onto the input shaft.
3rd Gear Side:
4th Gear Side:
A
B
A > B
C136402E01
6th Gear Side:
5th Gear Side:
C136401E01
F051098E01
MT–52
RA61F MANUAL TRANSMISSION – INPUT SHAFT
MT
(b) Using SST and a press, install the No. 2 clutch hub
onto the input shaft.
SST
09308-14010
HINT:
Align the convex portion of the synchronizer ring
with the groove of the clutch hub.
(c) Install the clutch hub and confirm that the gear and
synchronizer ring move smoothly.
7.
INSTALL CLUTCH HUB NO.2 SETTING 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.
8.
INSTALL NO. 2 SYNCHRONIZER RING SET
(a) Coat the No. 2 synchronizer ring set with gear oil,
then install it onto the input shaft.
SST
F051618E01
D033657E01
Part No.
Thickness: mm (in.)
Mark
90520-42012
1.77 to 1.82
(0.0697 to 0.0717)
A
90520-42013
1.82 to 1.87
(0.0717 to 0.0736)
B
90520-42014
1.87 to 1.92
(0.0736 to 0.0756)
C
90520-42015
1.92 to 1.97
(0.0756 to 0.0776)
D
90520-42016
1.97 to 2.02
(0.0776 to 0.0795)
E
90520-42017
2.02 to 2.07
(0.0795 to 0.0815)
F
90520-42018
2.07 to 2.12
(0.0815 to 0.0835)
G
F051095E01
RA61F MANUAL TRANSMISSION – INPUT SHAFT
MT–53
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9.
INSTALL SPACER
(a) Coat the spacer with gear oil, and install it onto the
input shaft.
10. INSTALL 3RD GEAR NEEDLE ROLLER BEARING
(a) Coat the 3rd gear needle roller bearing with gear oil,
and install it onto the input shaft.
11. INSTALL STRAIGHT PIN
(a) Install the straight pin into the input shaft.
12. INSTALL 3RD GEAR
(a) Coat the 3rd gear with gear oil, and install it onto the
input shaft.
13. INSTALL 3RD GEAR THRUST WASHER
(a) Coat the 3rd gear thrust washer with gear oil, and
install it onto the input shaft.
HINT:
Align the straight pin with the groove of the gear
thrust washer and install it.
F051094E01
F051093E01
F051092E01
F051091E01
F051090E01
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