Toyota FJ Cruiser (GSJ 10, 15 series). Instruction — part 430

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RA61F MANUAL TRANSMISSION – COUNTER GEAR AND REVERSE IDLER GEAR

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16. REMOVE NO. 1 SYNCHRONIZER RING SET (FOR

1ST GEAR)
(a) Remove the No. 1 synchronizer ring set from the

counter gear.

17. REMOVE CLUTCH HUB NO.1 SHAFT SNAP RING

(a) Using a snap ring expander, remove the snap ring

from the counter gear.

18. REMOVE COUNTER SHAFT 2ND SPEED GEAR

(a) Using a press, remove the counter shaft 2nd speed

gear together with the No. 1 transmission clutch hub
from the counter gear.
SST

09950-00020

19. REMOVE 2ND GEAR NEEDLE ROLLER BEARING

(a) Remove the 2nd needle roller bearing from the

counter gear.

20. REMOVE NO. 1 SYNCHRONIZER RING SET (FOR

2ND GEAR)
(a) Remove the No. 1 synchronizer ring set from the

2nd gear.

C136407

D033696E01

SST

F051632E01

F051551E01

F051633E01

RA61F MANUAL TRANSMISSION – COUNTER GEAR AND REVERSE IDLER GEAR

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21. REMOVE NO. 1 TRANSMISSION CLUTCH HUB

(a) Remove the hub sleeve, 3 synchromesh shifting

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

22. REMOVE SNAP RING COUNTER GEAR REAR

BEARING
(a) Using a snap ring expander, remove the snap ring

from the counter gear.

23. REMOVE RADIAL BALL BEARING INNER RACE

(a) Using SST and a press, remove the needle roller

bearing inner race.
SST

09950-00020

INSPECTION

1.

INSPECT COUNTER GEAR
(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
counter gear.

Clutch Hub

Hub Sleeve

Synchromesh Shifting Key

Ball

Spring

F051634E02

D033689E01

SST

F051635E01

F051553E01

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RA61F MANUAL TRANSMISSION – COUNTER GEAR AND REVERSE IDLER GEAR

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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 diameters are less than the minimum,
replace the counter gear shaft.

2.

INSPECT COUNTERSHAFT REVERSE GEAR
(a) Using a cylinder gauge, measure the inside

diameter of the reverse 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 reverse gear.

3.

INSPECT COUNTERSHAFT GEAR 1ST SPEED
(a) Using a cylinder gauge, measure the inside

diameter of the 1st gear.
Standard inside diameter:

54.015 to 54.040 mm (2.1266 to 2.1276 in.)

Maximum inside diameter:

54.040 mm (2.1276 in.)

If the inside diameter exceeds the maximum,
replace the 1st gear.

4.

INSPECT COUNTER SHAFT 2ND SPEED GEAR
(a) Using a cylinder gauge, measure the inside

diameter of the 2nd gear.
Standard inside diameter:

60.015 to 60.040 mm (2.3628 to 2.3638 in.)

Maximum inside diameter:

60.040 mm (2.3638 in.)

If the inside diameter exceeds the maximum,
replace the 2nd gear.

A B

C

D

E

D033700E01

Part

Outer diameter mm (in.)

A

34.002 to 34.015 (1.3387 to 1.3392)

B

36.985 to 37.000 (1.4561 to 1.4567)

C

47.985 to 48.000 (1.8892 to 1.8898)

D

53.985 to 54.000 (2.1254 to 2.1260)

E

34.002 to 34.015 (1.3387 to 1.3392)

Part

Outer diameter mm (in.)

A

34.002 (1.3387)

B

36.985 (1.4561)

C

47.985 (1.8892)

D

53.985 (2.1254)

E

34.002 (1.3387)

F051555E01

F051556E01

F051557E01

RA61F MANUAL TRANSMISSION – COUNTER GEAR AND REVERSE IDLER GEAR

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5.

INSPECT NO. 3 TRANSMISSION HUB SLEEVE
(a) Using vernier calipers, measure the width of the No.

3 transmission hub sleeve groove (A) and the
thickness of the claw part on the gear shift fork No. 4
(B), and calculate the clearance.
Standard clearance (A - B):

0.26 to 0.84 mm (0.0102 to 0.0331 in.)

If the clearance is outside the specification, replace
the No. 3 transmission hub sleeve and No. 4 gear
shift fork.

6.

INSPECT NO. 1 TRANSMISSION HUB SLEEVE
(a) Check the sliding condition between the No. 1

transmission hub and No. 1 transmission hub
sleeve.

(b) Check that the spline gear teeth of the No. 1

transmission hub sleeve are not worn.

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

1 transmission hub sleeve groove (A) and the
thickness of the claw part on the No. 1 gear shift fork
(B), and calculate the clearance.
Standard clearance (A - B):

0.15 to 0.35 mm (0.0059 to 0.0138 in.)

If the clearance is outside the specification, replace
the No. 1 transmission hub sleeve and No. 1 gear
shift fork.

B

A

F051559E01

C067843E01

B

A

F051558E01