Toyota FJ Cruiser (GSJ 10, 15 series). Instruction - part 427

MT–54

RA61F MANUAL TRANSMISSION  –  INPUT SHAFT

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14. INSTALL GEAR THRUST WASHER 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.

15. INSTALL SHAFT SNAP RING

(a) Coat the shaft snap ring with gear oil, and install it 

onto the input shaft.

16. INSTALL 6TH GEAR NEEDLE ROLLER BEARING

(a) Coat the 6th gear needle roller bearing with gear oil, 

and install it onto the input shaft.

D033654E01

Part No.

Thickness: mm (in.)

Mark

90520-39026

2.07 to 2.12

(0.0815 to 0.0835)

A

90520-39027

2.12 to 2.17

(0.0835 to 0.0854)

B

90520-39028

2.17 to 2.22

(0.0854 to 0.0874)

C

90520-39029

2.22 to 2.27

(0.0874 to 0.0894)

D

90520-39030

2.27 to 2.32

(0.0894 to 0.0913)

E

90520-39031

2.32 to 2.37

(0.0913 to 0.0933)

F

F051088E01

F051087E01

RA61F MANUAL TRANSMISSION  –  INPUT SHAFT

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17. INSTALL 6TH GEAR

(a) Install the 6th gear onto the input shaft.
(b) Install the synchronizer ring onto the input shaft.
(c) Using SST and a press, install the clutch hub onto 

the input shaft.
SST

09309-37010, 09950-00020

(d) Install the clutch hub and confirm that the gear and 

synchronizer ring move smoothly.

18. INSTALL TRANSMISSION CLUTCH HUB NO.3 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 brass bar and a hammer, install the snap 

ring onto the input shaft.

SST

SST

F051619E01

F051105E01

Part No.

Thickness: mm (in.)

Mark

90520-33022

2.10 to 2.15

(0.0827 to 0.0847)

A

90520-33023

2.15 to 2.20

(0.0847 to 0.0866)

B

90520-33024

2.20 to 2.25

(0.0866 to 0.0886)

C

90520-33025

2.25 to 2.30

(0.0886 to 0.0906)

D

90520-33026

2.30 to 2.35

(0.0906 to 0.0925)

E

90520-33027

2.35 to 2.40

(0.0925 to 0.0945)

F

90520-33028

2.40 to 2.45

(0.0945 to 0.0965)

G

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RA61F MANUAL TRANSMISSION  –  INPUT SHAFT

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19. INSPECT 6TH GEAR THRUST CLEARANCE

(a) Using a dial indicator, measure the 6th gear thrust 

clearance.
Standard clearance:

0.20 to 0.49 mm (0.0079 to 0.0193 in.)

If the clearance is outside the specification, replace 
the defective gear, spacer or shaft.

20. INSPECT 3RD GEAR THRUST CLEARANCE

(a) Using a feeler gauge, measure the 3rd gear thrust 

clearance.
Standard clearance:

0.09 to 0.52 mm (0.0035 to 0.0205 in.)

If the clearance is outside the specification, replace 
the defective gear, thrust washer, clutch hub or 
shaft.

21. INSPECT 4TH GEAR THRUST CLEARANCE

(a) Using a dial indicator, measure the 4th gear thrust 

clearance.
Standard clearance:

0.12 to 0.38 mm (0.0047 to 0.0150 in.)

If the clearance is outside the specification, replace 
the defective gear, clutch hub or shaft.

22. INSPECT 6TH GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 6th gear radial 

clearance.
Standard clearance:

0.015 to 0.065 mm (0.0006 to 0.0026 in.)

If the clearance is outside the specification, replace 
the defective gear, needle roller bearing or shaft.

23. INSPECT 3RD GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 3rd gear radial 

clearance.
Standard clearance:

0.015 to 0.067 mm (0.0006 to 0.0026 in.)

If the clearance is outside the specification, replace 
the defective gear, needle roller bearing or shaft.

F051109E01

F051110E01

F051111E01

F051106E01

F051107E01

RA61F MANUAL TRANSMISSION  –  INPUT SHAFT

MT–57

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24. INSPECT 4TH GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 4th gear radial 

clearance.
Standard clearance:

0.015 to 0.067 mm (0.0006 to 0.0026 in.)

If the clearance is outside the specification, replace 
the defective gear, needle roller bearing or shaft.

F051108E01