Transmission

Page

CUTAWAY VIEW 3-2

4-SPEED TRANSMISSION (H41 & H42) ... 3-3 3-SPEED TRANSMISSION (J30) 3-42

CUTAWAY VIEW

4-Speed Manual Transmission (H41 & H42) & Transfer

How Dismantle Manual Transmission

3-Speed Manual Transmission (J30) & Transfer

4-SPEED TRANSMISSION (H41 & H42)

REMOVAL

Remove From Vehicle

1. Drain the transmission and transfer oil.

2. Remove the parts in the numerical order shown in the figure.

Cowling Drain Land Cruiser

1 Battery Terminal 4. Heater Duct

2 Scuff Plate 5. Carpet or Mat

3 Cowl Side Trim

1 Battery Terminal 4. Heater Duct

2 Scuff Plate 5. Carpet or Mat

3 Cowl Side Trim

Land Cruiser Speedometer Shaft

6. Shift Lever Knob & Transfer Knob 7 Service Hole Cover with boot

8. Back-up Light Switch Connector

Land Cruiser 120 Shift Lever Retainer

9. Shift Lever

SST [09305-55010] 10. Transfer Shift Lever

Under Guard

' ^ v £

4L

V

i p -

hi

B^jL

I^qB

12. Speedometer Cable

13. Front Propeller Shaft

14. Rear Propeller Shaft

1 5. Starter Motor (For BJ Series)

16. Clutch Release Cylinder (For BJ Series)

1 7. Tachometer Sensor (For BJ, HJ Series)

18. Engine Rear Supportmember

19. Transmission & Transfer

0 Support the transmission and transfer assembly with jacks and a rope, and remove.

Restoration Toyota Transmission

TRANSMISSION GEAR & CASE

REMOVAL

1. Remove the parts in the numerical order shown in the figure.

Transfer

TRANSFER DISASSEMBLY SECTION Fig. 4-1 to 4-24

Separate the transfer from the transmission.

2. Disassemble the parts in the numerical order shown in the figure.

Toyota Land Cruiser Fj4 Engine

2. Spacer

3. Back-up Light Switch

4. Case Cover

5. Front Bearing Retainer

3. Disassemble the parts in the numerical order shown in the figure.

Toyota Land Cruiser Gearbox Repair

Snap Ring Bearing Snap Ring Bearing Input Shaft Snap Ring

12. Bearing

13. Output Shaft 14 Countershaft

1 5. Reverse Idler Gear Shaft

16. Reverse Idler Gear

17 Reverse Shift Arm

Disassemble the parts in the numerical order shown in the figure.

20 21 19 18

Thrust Washer Pin

1st Gear

21. Bearing

22. Synchronizer Ring

23. Snap Ring

24. No.2 Clutch Hub, Sleeve & Synchronizer Ring

25. 3rd Gear

26. Bushing

27. Ball

28. 2nd Gear

29. Bearing

Sst 09905 00012
Remove the snap ring with SST. SST [09905-00012] "
Sst 09905 00012

Remove the bearing with SST. SST [09950-20014]

Remove the bearing with SST. SST [09950-20014]

Remove the snap ring with SST. ** SST [09905-00012]

Sst 09905 00012

Remove the input shaft assembly from the case with SST. SST [09910-00014]

Remove the input shaft assembly from the case with SST. SST [09910-00014]

Measure the 3rd and 2nd gear thrust clearance.

Thrust clearance:

Measure the 1st gear and sleeve thrust clearance.

Thrust clearance:

Toyota Land Cruiser Bj4 Engine
Remove the snap ring with SST. SST [09905-00012]

Fig 3-19

Fig 3-19

Sst 09905 00012
Remove the bearing with SST. SST [09950-20014]
09316 60010

Remove the snap ring with SST. SST [09905-00012]

Hold the 1st gear tightly against the other gears and pull out the output shaft assembly from the case.

When pulling out the assembly, hold the gears in place to keep them from sliding off the shaft.

Drive out the reverse idler gear shaft toward the rear.

Remove the snap ring with SST. SST [09905-00012]

Toyota Fj4

INSPECTION

Wash the disassembled parts and inspect them as described below. Replace any part found defective.

HD r

Transmission Case & Front Bearing Retainer

Inspect for wear or damage.

Sst 09905 00012

| Replace The Front Bearing Retainer Oil Seal

01. Remove the oil seal by prying with a driver.

2. Tap in the oil seal with SST. SST [09316-60010]

Toyota Land Cruiser Wiper Repair

Check the clearance between the oil seal front end and retainer.

Output Shaft & Bushing

1. Inspect the shaft surfaces contacting the bearings and gears for wear or damage.

2. Inspect the bushing for wear or damage.

1st, 2nd, 3rd Gear & Bearing

1. Inspect the gears for wear or damage at the teeth, thrust faces, inside diameter, and coned surfaces.

2. Inspect the output shaft rear bearing and the roller bearings for wear or damage.

Measure the oil clearance.

3rd gear oil clearance (A - B): STD 0.065 - 0.115 mm

Toyota 14b 2nd And 3rd Gear Shifting Key

Synchronizer Ring

1. Fit the synchronizer ring on the gear and measure the clearance.

3rd & 4th gear synchronizer ring clearance:

Limit 0.8 mm

Diesel Landcruiser Synchronizer Problem

2. Measure the No.1 synchronizer ring dimension.

Dimension: Limit

1st gear 2.8 mm

Hub Sleeve

Clutch Hub Sleeve, Clutch Hub,

Shifting Key & Shifting Key Spring

1. Disassemble the clutch hub and sleeve.

2. Inspect the splines of hub and hub sleeve for wear or damage.

3. Inspect the center humped part of keys for wear or damage.

4. Inspect the key springs for weakening or damage.

Remove Clutch Hub And 5th Gear

Check the clearance between the sleeve and shift fork.

Shift fork to hub sleeve clearance: Limit 0.8 mm

6. Hub and hub sleeve are parts having directionality.

Install the key springs positioned so that their end gaps will not be in line.

Input Shaft

1. Inspect the gear teeth, splines, coned sur-rfaces, and bearing for wear or deamage.

2. Inspect the shaft inner surface that contact on the needle roller bearing for wear or damage.

Toyota Fj4

Replace The Input Shaft Bearing

1. Remove the snap ring with SST. SST [09905-00012]

2. Remove the bearing with SST. SST [09950-20014]

3. Install the new bearing with a press.

4. Select a snap ring of the thickness that will allow minimum axial play, and install it on the shaft.

Snap ring size

Part No.

Thickness mm (in.)

90520-36015

3.31 - 3.42 (0.1303 - 0.1346)

90520-36016

3.20 - 3.31 (0.1260 - 0.1303)

Counter Gear

1. Inspect the counter gear teeth for wear or damage.

2. Inspect the front and rear bearings for wear or damage.

-SST

-SST

3. Rear bearing inner race replacement. <1) Remove the inner race with SST.

SST [09602-10010] (2) Install the new inner race with SST. SST [09515-21010]

3. Rear bearing inner race replacement. <1) Remove the inner race with SST.

SST [09602-10010] (2) Install the new inner race with SST. SST [09515-21010]

Make sure to position the inner race so that its flanged side will be directed toward the front.

Reverse Idler Gear, bushing & Shaft

1. Inspect the gear, bushing, and shaft for wear or damage.

2. Measure the reverse idle gear gear bushing and shaft oil clearance. Oil clearance: Limit 0.16 mm

Reverse Shift Arm

1. Inspect the shift arm shoeO) for wear or damage.

Shoe thickness: Limit 8.1 mm

2. Inspect the shift arm at the shoe mounting^) and pivot mounting(3) for wear or damage.

3. Inspect the pivot(4) for wear or damage.

4. Inspect the clearance between the shoe and reverse idler gear slot.

Clearance:

Limit 0.7 mm

TRANSMISSION CASE COVER DISASSEMBLY

Disassemble the parts in the numerical order shown in the figure.

Gear Shifter Slotted Shaft

1.

Slotted Spring Pin

7.

Locking Ball & Spring

2.

3rd, 4th Shift fork Shaft & Blind Plug

8

Reverse Shift Head

3.

3rd, 4th Shift Fork &

9.

Slotted Spring Pin

3rd, 4th Shift Head

10.

1st, 2nd Shift Fork Shaft & Blind Plug

4

Locking ball & Spring

11

1st & 2nd Shift Fork

5.

Slotted Spring Pin

12.

Locking Ball & Spring

6

Reverse Shift Fork Shaft & Blind Plug

13.

Interlock Pin

Gear Shifter Slotted Shaft
Drive out the slotted spring pin.
Gear Shifter Slotted Shaft

0 Drive out the shift fork shaft together with the blind plug.

Do not damage the case cover.

Lockable Hand Hole Cover

™—1 Cover the service hole with your hand to pre-^^ vent locking ball from flying out.

Remove the locking ball and the spring with magnet.
Fig. 3-49
Lockable Hand Hole Cover

Remove the locking ball and the spring with magnet.

Cover the service hole with your hand to prevent the locking ball from flying out.

Drive out the slotted spring pin.

Drive out the shift fork shaft together with blined plug.

Drive out the slotted spring pin.

Drive out the shift fork shaft together with blined plug.

Cover the service hole with your hand to prevent the locking ball from flying out.

Remove the locking ball and the spring with magnet.

Toyota Fj4
Drive out the slotted spring pin.

Drive out the fork shaft together with the blind plug.

Cover the service hole with your hand to prevent locking ball from flying put.

Remove the interlock pin with magnet.

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Responses

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    7 years ago
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    9 months ago
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