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

MT

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

MT

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