Toyota FJ Cruiser (GSJ 10, 15 series). Instruction - part 477

SERVICE SPECIFICATIONS  –  RA61F MANUAL TRANSMISSION

SS–33

SS

Clutch hub No. 2 setting shaft snap ring

Mark A

B

C
D

E

F

G

1.77 to 1.82 mm (0.0697 to 0.0717 in.)
1.82 to 1.87 mm (0.0717 to 0.0736 in.)
1.87 to 1.92 mm (0.0736 to 0.0756 in.)
1.92 to 1.97 mm (0.0756 to 0.0776 in.)
1.97 to 2.02 mm (0.0776 to 0.0795 in.)
2.02 to 2.07 mm (0.0795 to 0.0815 in.)
2.07 to 2.12 mm (0.0815 to 0.0835 in.)

Gear thrust washer shaft snap ring

Mark A

B

C
D

E

F

2.07 to 2.12 mm (0.0815 to 0.0835 in.)
2.12 to 2.17 mm (0.0835 to 0.0854 in.)
2.17 to 2.22 mm (0.0854 to 0.0874 in.)
2.22 to 2.27 mm (0.0874 to 0.0894 in.)
2.27 to 2.32 mm (0.0894 to 0.0913 in.)
2.32 to 2.37 mm (0.0913 to 0.0933 in.)

Transmission clutch hub No. 3 shaft snap ring

Mark A

B

C
D

E

F

G

2.10 to 2.15 mm (0.0827 to 0.0847 in.)
2.15 to 2.20 mm (0.0847 to 0.0866 in.)
2.20 to 2.25 mm (0.0866 to 0.0886 in.)
2.25 to 2.30 mm (0.0886 to 0.0906 in.)
2.30 to 2.35 mm (0.0906 to 0.0925 in.)
2.35 to 2.40 mm (0.0925 to 0.0945 in.)
2.40 to 2.45 mm (0.0945 to 0.0965 in.)

Output shaft inside diameter

STD:

MAX:

45.017 to 45.025 mm (1.7723 to 1.7726 in.)
45.025 mm (1.7726 in.)

Synchronizer ring back and gear spline end clearance

STD:

MIN:

0.70 to 1.50 mm (0.0276 to 0.0591 in.)
0.70 mm (0.0276 in.)

Reverse gear thrust clearance

-

0.125 to 0.375 mm (0.0049 to 0.0148 in.)

1st gear thrust clearance

-

0.10 to 0.43 mm (0.0039 to 0.0169 in.)

2nd gear thrust clearance

-

0.10 to 0.43 mm (0.0039 to 0.0169 in.)

Reverse gear radial clearance

-

0.015 to 0.065 mm (0.0006 to 0.0026 in.)

1st gear radial clearance

-

0.015 to 0.067 mm (0.0006 to 0.0026 in.)

2nd gear radial clearance

-

0.015 to 0.067 mm (0.0006 to 0.0026 in.)

Counter gear runout

MAX:

0.03 mm (0.0012 in.)

Counter gear outer diameter

STD: A

B

C
D

E

MIN: A

B

C
D

E

34.002 to 34.015 mm (1.3387 to 1.3392 in.)
36.985 to 37.000 mm (1.4561 to 1.4567 in.)
47.985 to 48.000 mm (1.8892 to 1.8898 in.)
53.985 to 54.000 mm (2.1254 to 2.1260 in.)
34.002 to 34.015 mm (1.3387 to 1.3392 in.)
34.002 mm (1.3387 in.)
36.985 mm (1.4561 in.)
47.985 mm (1.8892 in.)
53.985 mm (2.1254 in.)
34.002 mm (1.3387 in.)

Reverse gear inside diameter

STD:

MAX:

51.015 to 51.040 mm (2.0085 to 2.0095 in.)
51.040 mm (2.0095 in.)

1st gear inside diameter

STD:

MAX:

54.015 to 54.040 mm (2.1266 to 2.1276 in.)
54.040 mm (2.1276 in.)

2nd gear inside diameter

STD:

MAX:

60.015 to 60.040 mm (2.3628 to 2.3638 in.)
60.040 mm (2.3638 in.)

Gear shift fork No. 4 claw and glove of the transmission hub 
sleeve No. 3 clearance

-

0.26 to 0.84 mm (0.0102 to 0.0331 in.)

Gear shift fork No. 1 claw and glove of the transmission hub 
sleeve No. 1 clearance

-

0.15 to 0.35 mm (0.0059 to 0.0138 in.)

Reverse gear synchronizer ring back and reverse gear 
spline end clearance

STD:

MIN:

0.70 to 1.30 mm (0.0276 to 0.0512 in.)
0.70 mm (0.0276 in.)

1st gear synchronizer ring back and 1st gear spline end 
clearance

STD: Inner

Middle

Outer

MIN: Inner

Middle

Outer

1.48 to 2.12 mm (0.0583 to 0.0835 in.)
0.68 to 1.92 mm (0.0268 to 0.0756 in.)
0.88 to 1.72 mm (0.0346 to 0.0677 in.)
1.48 mm (0.0583 in.)
0.68 mm (0.0268 in.)
0.88 mm (0.0346 in.)

SS–34

SERVICE SPECIFICATIONS  –  RA61F MANUAL TRANSMISSION

SS

2nd gear synchronizer ring back and 2nd gear spline end 
clearance

STD: Inner

Middle

Outer

MIN: Inner

Middle

Outer

1.48 to 2.12 mm (0.0583 to 0.0835 in.)
0.68 to 1.92 mm (0.0268 to 0.0756 in.)
0.88 to 1.72 mm (0.0346 to 0.0677 in.)
1.48 mm (0.0583 in.)
0.68 mm (0.0268 in.)
0.88 mm (0.0346 in.)

Counter gear rear bearing snap ring

Mark A

B

C
D

E

F

G

H

J

K

L

M

2.35 to 2.40 mm (0.0925 to 0.0945 in.)
2.40 to 2.45 mm (0.0945 to 0.0965 in.)
2.45 to 2.50 mm (0.0965 to 0.0984 in.)
2.50 to 2.55 mm (0.0984 to 0.1004 in.)
2.55 to 2.60 mm (0.1004 to 0.1024 in.)
2.60 to 2.65 mm (0.1024 to 0.1043 in.)
2.65 to 2.70 mm (0.1043 to 0.1063 in.)
2.70 to 2.75 mm (0.1063 to 0.1083 in.)
2.75 to 2.80 mm (0.1083 to 0.1102 in.
2.80 to 2.85 mm (0.1102 to 0.1122 in.)
2.85 to 2.90 mm (0.1122 to 0.1142 in.)
2.90 to 2.95 mm (0.1142 to 0.1161 in.)

Clutch hub No. 1 shaft snap ring

Mark A

B

C
D

E

F

G

2.28 to 2.33 mm (0.0898 to 0.0917 in.)
2.33 to 2.38 mm (0.0917 to 0.0937 in.)
2.38 to 2.43 mm (0.0937 to 0.0957 in.)
2.43 to 2.48 mm (0.0957 to 0.0976 in.)
2.48 to 2.53 mm (0.0976 to 0.0996 in.)
2.53 to 2.58 mm (0.0996 to 0.1016 in.)
2.58 to 2.63 mm (0.1016 to 0.1035 in.)

Counter gear front bearing snap ring

Mark A

B

C
D

E

F

G

H

J

K

L

M

2.35 to 2.40 mm (0.0925 to 0.0945 in.)
2.40 to 2.45 mm (0.0945 to 0.0965 in.)
2.45 to 2.50 mm (0.0965 to 0.0984 in.)
2.50 to 2.55 mm (0.0984 to 0.1004 in.)
2.55 to 2.60 mm (0.1004 to 0.1024 in.)
2.60 to 2.65 mm (0.1024 to 0.1043 in.)
2.65 to 2.70 mm (0.1043 to 0.1063 in.)
2.70 to 2.75 mm (0.1063 to 0.1083 in.)
2.75 to 2.80 mm (0.1083 to 0.1102 in.)
2.80 to 2.85 mm (0.1102 to 0.1122 in.)
2.85 to 2.90 mm (0.1122 to 0.1142 in.)
2.90 to 2.95 mm (0.1142 to 0.1161 in.)

SERVICE SPECIFICATIONS  –  RA61F MANUAL TRANSMISSION

SS–35

SS

TORQUE SPECIFICATIONS

Part tightened

N*m

kgf*cm

ft.*lbf

Transmission filler plug x Manual transmission

37

377

27

Manual transmission case cover x Manual transmission

12

117

8.5

Manual transmission x Engine for bolt A

72

730

53

Manual transmission x Engine for bolt B

37

380

28

Manual transmission x Engine mounting insulator rear 
No. 1

65

663

48

Frame crossmember sub-assembly No. 3 x Body

72

734

53

Frame crossmember sub-assembly No. 3 x Manual 
transmission

19

189

14

Manifold stay x Manual transmission

40

408

30

No. 2 manifold stay x Manual transmission

40

408

30

Battery x Negative battery terminal cable

3.9

40

35 in.*lbf

Gear shift fork No. 2 x Gear shift fork shaft No. 2

20

199

14

Gear shift fork No. 3 x Gear shift fork shaft No. 3

20

199

14

Transmission front case x Plug

39

400

29

Transmission front case x Interlock bracket

21

214

15

Transmission front case x Back-up light switch

44

449

33

Shift & select lever x Shift & select lever shaft

33

340

25

Transmission middle case x Drain plug

37

377

27

Transmission front case x Transmission middle case

40

408

30

Reverse idler gear shaft bolt x Reverse idler gear shaft

28

286

21

Transmission oil separator x Transmission middle case

8.5

87

75 in.*lbf

Bearing lock plate x Transmission rear case

11

115

8.3

Transmission rear case x Filler plug

37

377

27

Transmission rear case x Transmission middle case

40

408

30

Transmission rear case x Shift detent ball plug

25

250

18

Transmission rear case x Transmission case cover

18

184

13

Shift lever housing x Shift & select lever shaft

33

340

25

Floor shift control shift lever retainer sub-assembly x 
Transmission rear case

20

204

15

Front suspension member bracket LH x Body

33

336

24

Front suspension member bracket RH x Body

33

336

24

Accumulator to flexible hose tube x Flexible hose

15

153

11

Hose tube bracket x Manual transmission 

19

194

14

Propeller shaft heat insulator x No. 3 frame 
crossmember sub-assembly

16

160

12

SS–36

SERVICE SPECIFICATIONS  –  VF2A TRANSFER

SS

VF2A TRANSFER

SERVICE DATA

Rear output shaft

Drive sprocket thrust clearance

Standard

0.10 to 0.25 mm (0.0039 to 0.0098 in.)

Maximum

0.25 mm (0.0098 in.)

Output shaft rear journal surface diameter

(part A) Minimum

27.98 mm (1.1016 in.)

(part B) Minimum

36.98 mm (1.4561 in.)

Drive sprocket radial clearance

Standard

0.010 to 0.055 mm (0.0004 to 0.0022 in.)

Maximum

0.055 mm (0.0022 in.)

Front drive clutch sleeve to gear shift fork No. 
1 clearance

Maximum

1.0 mm (0.039 in.)

High and low clutch sleeve to gear shift fork 
No. 2 clearance

Maximum

1.0 mm (0.039 in.)

Output shaft snap ring thickness

Mark K

2.00 to 2.05 mm (0.0787 to 0.0807 in.)

Mark L

2.05 to 2.10 mm (0.0807 to 0.0827 in.)

Mark A

2.10 to 2.15 mm (0.0827 to 0.0846 in.)

Mark B

2.15 to 2.20 mm (0.0846 to 0.0866 in.)

Mark C

2.20 to 2.25 mm (0.0866 to 0.0886 in.)

Mark D

2.25 to 2.30 mm (0.0886 to 0.0906 in.)

Mark E

2.30 to 2.35 mm (0.0906 to 0.0925 in.)

Mark F

2.35 to 2.40 mm (0.0925 to 0.0945 in.)

Mark G

2.40 to 2.45 mm (0.0945 to 0.0965 in.)

Mark H

2.45 to 2.50 mm (0.0965 to 0.0984 in.)

Mark J

2.50 to 2.55 mm (0.0984 to 0.1004 in.)

Input shaft

Input shaft outside diameter

Minimum

47.59 mm (1.8736 in.)

Input shaft inside diameter

Maximum

39.14 mm (1.5409 in.)

Synchronizer ring back to input shaft spline 
clearance

Standard

1.05 to 1.85 mm (0.0413 to 0.0728 in.)

Minimum

1.05 mm (0.0413 in.)

Input gear stopper shaft snap ring thickness

Mark A

2.10 to 2.15 mm (0.0827 to 0.0846 in.)

Mark B

2.15 to 2.20 mm (0.0846 to 0.0866 in.)

Mark C

2.20 to 2.25 mm (0.0866 to 0.0886 in.)

Mark D

2.25 to 2.30 mm (0.0886 to 0.0906 in.)

Mark E

2.30 to 2.35 mm (0.0906 to 0.0925 in.)

Mark F

2.35 to 2.40 mm (0.0925 to 0.0945 in.)

Mark G

2.40 to 2.45 mm (0.0945 to 0.0965 in.)

Mark H

2.45 to 2.50 mm (0.0965 to 0.0984 in.)

Mark J

2.50 to 2.55 mm (0.0984 to 0.1004 in.)

Mark K

2.55 to 2.60 mm (0.1004 to 0.1024 in.)

Mark L

2.60 to 2.65 mm (0.1024 to 0.1043 in.)

Mark M

2.65 to 2.70 mm (0.1043 to 0.1063 in.)

Mark N

2.70 to 2.75 mm (0.1063 to 0.1083 in.)

Mark P

2.75 to 2.80 mm (0.1083 to 0.1102 in.)

Mark Q

2.80 to 2.85 mm (0.1102 to 0.1122 in.)

Mark R

2.85 to 2.90 mm (0.1122 to 0.1142 in.)

Mark S

2.90 to 2.95 mm (0.1142 to 0.1161 in.)

Mark T

2.95 to 3.00 mm (0.1161 to 0.1181 in.)

Mark U

3.00 to 3.05 mm (0.1181 to 0.1201 in.)

Planetary gear