Toyota FJ Cruiser (GSJ 10, 15 series). Instruction — part 419

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RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT

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(b) Using a plastic hammer, carefully tap out the rear

case.
HINT:
Place the brass bar against the rib portion of the
case.

7.

REMOVE MANUAL TRANSMISSION FILLER PLUG
(a) Remove the 2 transmission filler plugs and 2

gaskets from the transmission rear case.

8.

REMOVE EXTENSION HOUSING OIL RECEIVER
PIPE
(a) Remove the extension housing oil receiver pipe

from the transmission rear case.

9.

REMOVE OIL SEPARATOR PACKING SEAL
(a) Remove the oil separator packing seal from the

transmission rear case.

10. REMOVE OUTPUT SHAFT REAR BEARING OUTER

RACE
(a) Using SST, remove the 2 bearing outer races.

SST

09308-00010

D033739

F051572

F051573

F051828

SST

SST

D033748E01

RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT

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11. REMOVE COUNTER GEAR REAR RADIAL BALL

BEARING
(a) Remove the bolt, then remove the bearing lock

plate.

(b) Using SST, remove the counter gear rear radial ball

bearing from the transmission rear case.
SST

09308-00010

12. REMOVE TRANSMISSION OIL SEPARATOR

(a) Remove the 2 bolts, then remove the oil separator.

13. REMOVE REVERSE IDLER GEAR SHAFT BOLT

(a) Remove the reverse idler gear shaft bolt from the

transmission middle case.

14. REMOVE TRANSMISSION MIDDLE CASE

(a) Remove the 11 bolts, then remove the transmission

middle case.

D033746

SST

F051574E01

F051575

D033649

D033740

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RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT

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(b) Using a plastic hammer, carefully tap out the middle

case.
HINT:
Place the brass bar against the rib portion of the
case.

15. REMOVE DRAIN PLUG SUB-ASSEMBLY

(a) Remove the drain plug and gasket from the

transmission middle case.

16. REMOVE NO. 2 OIL RECEIVER PIPE

(a) Remove the No. 2 oil receiver pipe from the

transmission middle case.

17. REMOVE SHIFT AND SELECT LEVER SHAFT

(a) Remove the shift and select lever shaft from the

reverse gear shaft.

18. REMOVE SHIFT AND SELECT LEVER

(a) Remove the bolt, then remove the shift and select

lever.

(b) Remove the lock ball pin and spring from the shift

and select lever.

D033741

F051576

F051577

F051578

F051579

RA61F MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT

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19. REMOVE SHIFT AND SELECT LEVER CAM

(a) Using a screwdriver, remove the E ring and the shift

and select lever cam from the shift and select lever
shaft.

20. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

(a) Using SST, remove the back-up light switch and

gasket.
SST

09817-16011

21. INSPECT REVERSE IDLER GEAR THRUST

CLEARANCE
(a) Using a feeler gauge, measure the thrust clearance.

Standard clearance:

0.10 to 0.25 mm (0.0039 to 0.0098 in.)

Maximum clearance:

0.25 mm to (0.0098 in.)

If the clearance exceeds the maximum, replace the
reverse idler gear shaft, reverse idler gear or
transmission front case.

22. REMOVE REVERSE IDLER GEAR

(a) Remove the reverse idler gear shaft, needle roller

bearing and reverse idler gear.

23. INSPECT REVERSE IDLER GEAR RADIAL

CLEARANCE
(a) Using a dial indicator, measure the radial clearance.

Standard clearance:

0.015 to 0.050 mm (0.0006 to 0.0020 in.)

Maximum clearance:

0.050 mm (0.0020 in.)

If the clearance exceeds the maximum, replace the
needle roller bearing.

F051580

SST

F051581E01

D033776

D033634

D033777