Content

Clutch

Description

Trouble shooting

Adjustment

• Clutch pedal
• Clutch release fork
• Air bleeding

Clutch pedal

• Removal
• Inspection
• Installation

Clutch master cylinder

• Removal
• Disassembly
• Inspection
• Assembly
• Installation

Clutch release cylinder

• Removal
• Disassembly
• Inspection
• Assembly
• Installation

Clutch cover assembly

• Removal
• Disassembly
• Inspection
• Assembly
• Installation

Transmission and transfer

Description

Trouble shooting

3-Speed transmission and transfer

• Removal
• Disassembly
• Inspection
• Assembly
• Installation

4-speed transmission and transfer

• Removal
• Disassembly
• Inspection
• Assembly
• Installation

Control shaft and linkage (55 series)

• Removal
• Inspection
• Installation

Control shaft (40 series)

• Removal
• Inspection
• Installation

Transfer shift lever and linkage (55 series)

• Removal and disassembly
• Inspection
• Installation

Transfer shift lever and linkage (40 series)

Transfer front drive control

• Description
• Operation
• Removal
• Inspection
• Installation

Diaphragm cylinder and transfer front drive fork

• Removal
• Disassembly
• Inspection
• Assembly
• Installation

Propeller shaft

• Removal
• Disassembly
• Inspection
• Assembly
• Installation

Rear axle and rear suspension

Description

Trouble shooting

Rear axle shaft

• Removal and disassembly
• Inspection
• Installation

Differential

• Removal
• Disassembly
• Inspection
• Assembly and adjustment
• Installation

Rear suspension

• Removal
• Inspection and repair
• Installation

Front axle and front suspension

Description

Trouble shooting

Steering knuckle and axle shaft

• Ball joint type
• Removal and disassembly
• Inspection and repair
• Adjustment
• Assembly and installation
• Birfield constant velocity joint type
• Removal and disassembly
• Inspection and repair
• Adjustment
• Assembly and installation

Differential

• Removal
• Installation

Front suspension

• Removal
• Inspection and repair
• Installation

Steering

• Inspection
• Assembly
• Installation

Steering inter-mediate shaft and gear housing (55 seires)

• Removal
• Disassembly
• Inspection
• Steering gear housing
• Inter-mediate shaft
• Assembly and adjustment
• Inter-mediate shaft
• Steering gear housing
• Installation

Steering wheel and gear housing (40 series)

• Removal and installation
• Disassembly
• Inspection
• Assembly

Steering linkage

• Removal
• Disassembly
• Inspection
• Assembly
• Installation

Wheel and tires

• Tires
• Disc wheel
• Wheel balancing
• Tire rotation

Front end alignment

• Camber
• Caster
• King pin inclination
• Toe-in
• Side slip
• Front wheel turning angle

Brake

Description

Trouble shooting

Adjustment

• Brake pedal
• Brake shoe clearance
• Parking brake
• Air bleeding

Brake pedal

Brake master cylinder

• Removal and disassembly
• Inspection
• Assembly
• Installation

Brake line

• Flexible hose
• Brake tubes

Front brake

• Removal
• Inspection and repair
• Installation

Rear brake

• Removal
• Inspection and repair
• Installation

Parking brake

• Removal and disassembly
• Inspection
• Assembly and installation

Brake booster (OLD)

• Description
• Operation
• Trouble shooting
• Removal and disassembly
• Inspection
• Assembly
• Installation
• Performance test

Brake booster (NEW)

• Operation
• Trouble shooting
• Tadem master cylinder
• Brake booster
• Component parts
• Removal
• Disassembly
• Inspection
• Assembly
• Adjustment
• Installation
• Booster performance test

Frame

Description

• Inspection
• Repair and replacement

Front winch

Description

Power take-off

• Removal and disassembly
• Inspection
• Assembly
• Installation

Drive shaft

• Removal
• Disassembly
• Inspection
• Assembly
• Installation

Winch

• Removal
• Disassembly
• Inspection
• Assembly
• Installation

Body (WAGON)

• Description
• Hood and hood lock
• Front fender
• Radiator grille
• Lower shroud panel
• Front bumper
• Front door
• Front door window regulator
• Door window glass and ventilating window glass
• Front door lock
• Door lock cylinder
• Door outside handle
• Door lock remote control
• Door lock striker plate
• Rear door
• Rear door glass
• Rear door window requlator
• Rear door lock
• Rear door lock remote control
• Front windshield glass
• Weatherstrip
• Side window glass
• Tail gate
• Tail gate glass and regulator
• Tail gate regulator motor
• Tail gate lock
• Tail gate switch
• Back door (swing gate)
• Back door lock (rh)
• Back door lock (lh)
• Back door glass
• Roof headlining
• Front seat and rear seat
• Rear bumper
• Body mounting
• Front fender apron and dash panel
• Floor pan and transmision cover
• Side member
• Roof panel and cowl panel

Body (HARD TOP)

• Front fender
• Radiator gril
• Door
• Front windshield glass side windshield glass
• Rear drop gate
• Rear swing gate
• Rear gate
• Hard top roof
• Seat and seat track
• Uentilator
• Body mounting
• Body side panel
• Floor panel

Body (CANVAS TOP)

• Door
• Rear swing gate
• Top bow
• Canvas top

Body (PICK UP)

• Roof panel and back panel
• Seat and seat truck
• Rear body
• Cab mounting

Instruments

• Combination meter and speedometer (FJ55)
• Combination meter and speedometer (FJ40,43,45)
• Instrument panel and glove compartment

Body electrical (FJ55)

• Headlight
• Front turn signal light
• Rear combination light
• Back-up light
• License plate light
• Parking light
• Room light
• Reflector
• Ignition switch
• Lighting and wiper switchers
• Back-up light switch
• Water temperature sending gauge
• Fuel sending gauge
• Oil pressure switch
• Horn button
• Turn signal, dimmer and headlight flasher switch
• Horn
• Turn signal and hazard warning flashers
• Horn relay
• Wiper
• Wiring harness and grommet

Body electrical (FJ40,43,45)

• Headlamps
• Lamp bulb replacement
• Turn signal control
• Windshield wiper
• Switches
• Horns
• Wiring harness and grommet

Accessories and available equipment

• Heater (FJ55 series)
• Heater blower
• Heater radiator
• Heater control
• Heater (for rear seat occupants)
• Heater (FJ45 series)
• Windshield washer