Toyota FJ Cruiser (GSJ 10, 15 series). Instruction - part 421

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RA61F MANUAL TRANSMISSION  –  MANUAL TRANSMISSION UNIT

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REASSEMBLY

1.

INSTALL 1ST AND REVERSE SHIFT ARM
(a) Install the shift arm and shift arm pivot onto the 

interlock bracket.

(b) Install a new E-ring onto the shift arm pivot.

2.

INSTALL NO. 4 GEAR SHIFT FORK SHAFT
(a) Install the spring and ball onto the interlock bracket.
(b) Install the No. 4 shift fork shaft.

3.

INSTALL NO. 4 GEAR SHIFT FORK
(a) Install the No. 4 shift fork onto the No. 4 shift fork 

shaft .

(b) Using a pin punch (5 mm (0.20 in.)) and hammer, 

tap a new slotted pin into the No. 4 shaft fork and 
No. 4 shift fork shaft.
Drive in depth:

0 to 0.5 mm (0 to 0.050 in.)

4.

INSTALL NO. 1 GEAR SHIFT FORK
(a) Install the No. 1 shift fork and No. 2 shift head onto 

the No. 4 shift fork shaft.

(b) Using a pin punch (5 mm (0.20 in.)) and hammer, 

tap a new slotted pin into the No. 2 shaft head and 
No. 4 shift fork shaft.
Drive in depth:

0 to 0.5 mm (0 to 0.050 in.)

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5.

INSTALL NO. 1 GEAR SHIFT FORK SHAFT
(a) Apply MP grease to the No. 1 interlock pin and 

install it into the interlock bracket.

(b) Install the spring and ball into the interlock bracket.
(c) Install the No. 1 shift fork shaft onto the interlock 

bracket.
HINT:
Place the No. 4 shift fork shaft in the neutral 
position.

6.

INSTALL NO. 1 GEAR SHIFT HEAD
(a) Install the No. 1 shift head into the No. 1 shift fork 

shaft.

(b) Using a pin punch (5 mm (0.20 in.)) and hammer, 

tap a new slotted pin into the No. 1 shaft head and 
No. 1 shift fork shaft.
Drive in depth:

0 to 0.5 mm (0 to 0.050 in.)

7.

INSTALL NO. 2 GEAR SHIFT FORK SHAFT
(a) Apply MP grease to the No. 2 and No. 3 interlock 

pins, then install them onto the interlock bracket.

(b) Install the spring and ball into the interlock bracket.
(c) Install the No. 2 shift fork shaft onto the interlock 

bracket.
HINT:
Place the No. 3 and No. 4 shift fork shafts in the 
neutral position.

8.

INSTALL NO. 2 GEAR SHIFT FORK
(a) Install the No. 2 shift fork with the bolt.

Torque: 20 N*m (199 kgf*cm, 14 ft.*lbf)

9.

INSTALL NO. 3 GEAR SHIFT FORK SHAFT
(a) Apply MP grease to the No. 2 and No. 3 interlock 

pins, then install them onto the interlock bracket.

(b) Install the spring and ball into the interlock bracket.
(c) Install the No. 3 shift fork shaft onto the interlock 

bracket.
HINT:
Place the No. 2, No. 1 and No. 4 shift fork shafts in 
the neutral position.

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RA61F MANUAL TRANSMISSION  –  MANUAL TRANSMISSION UNIT

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10. INSTALL NO. 3 GEAR SHIFT FORK

(a) Install the No. 3 shift fork with the bolt.

Torque: 20 N*m (199 kgf*cm, 14 ft.*lbf)

11. INSTALL TRANSMISSION CASE OIL SEAL

(a) Using SST and a hammer, tap a new oil seal into 

the front case in accordance with the dimension 
specified in the illustration.
SST

09950-70010 (09951-07100), 09950-60010 
(09951-00470)

Dimension A:

60.0 to 60.8 mm (2.362 to 2.394 in.)

(b) Apply gear oil to the lip of the oil seal.

12. INSTALL FRONT BEARING SHAFT SNAP RING

(a) Using snap ring pliers, install the 2 snap rings.

13. INSTALL NO. 1 OIL RECEIVER PIPE

(a) Install the No. 1 oil receiver pipe onto the 

transmission front case.
HINT:
Align the convex portion of the oil receiver pipe with 
the cutout of the front case and install the oil 
receiver pipe onto the clutch housing.

14. INSTALL TRANSMISSION FRONT CASE

(a) Apply gear oil to all sliding and rotating parts.
(b) Provisionally install the output shaft, input shaft, 

counter gear shaft and control assembly, and tie 
them with a piece of rope or string.

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SST

A

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(c) Using a snap ring expander, extend the 2 snap rings 

and install the output shaft, input shaft, counter gear 
shaft and control assembly.
HINT:
Make sure that the snap ring is fitted into the 
grooves of the input shaft and front bearing of the 
counter gear shaft.

(d) Untie the output shaft, input shaft, counter gear 

shaft and control assembly.

(e) Using a hexagonal wrench (24 mm), install the plug 

onto the front case.
Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)

(f)

Install the interlock bracket with the 4 bolts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

15. INSTALL REVERSE IDLER GEAR

(a) Install the reverse idler gear, reverse idler gear 

bearing and reverse idler gear shaft.
HINT:
Make sure that the reverse idler gear faces the 
correct direction as shown in the illustration.
NOTICE:
Make sure that the hole in the reverse idler shaft 
is in the position shown in the illustration.

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