Description

Toyota FJ40, FJ43, FJ45, FJ60, BJ40 1980 Repair Manual

You have an old Land Cruiser in the bay—an FJ40 or maybe a BJ40—and you are staring at a clutch that won’t disengage or a steering box that leaks like a sieve. The aftermarket PDF you obtained from some forum tells you to “tighten the bolts to snug.” Snug means nothing. Snug gets you a pulled thread or a drip that comes back next week. This Toyota FJ40, FJ43, FJ45, FJ60, BJ40 1980 Repair Manual is the factory-issued answer to that guesswork. 851 pages of spec-verified procedure, written by the engineers who built the truck. No third-party re-interpretation. You get the same manual Toyota handed its own dealers.

Transmission: 57 Pages of Factory Procedure

Section 3 covers the transmission from page 3-1 through 3-57. That is 57 pages dedicated to the gearbox alone—disassembly, inspection, shim selection, and reassembly with the correct preload. Need the bearing preload spec? It is in there. Need the snap ring thickness alternatives? Page 3-42 lists every available ring by part number and thickness. You won’t find that in a Chilton’s. You will also find the exact torque sequence for the transmission case bolts. Following the factory sequence prevents warping the case. I have seen guys crack a transfer case adapter by skipping steps. Not with this manual.

Steering: 142 Pages of Linkage and Gearbox Work

Section 8 runs from 8-1 to 8-145. That is 145 pages on steering—recirculating ball gearbox, pitman arm, relay rod, idler arm, and the entire linkage. The factory includes the SST numbers for pulling the pitman arm without damaging the splines. If you try to use a pickle fork, you will tear the boot. Page 8-60 shows the correct puller and the torque for the sector shaft nut. 94 ft-lb. Not hand-tight. Not an impact gun until it stops. 94 ft-lb with a calibrated wrench. That is the difference between a job that passes inspection and a steering wheel that has 5 degrees of play next month.

Clutch: 24 Sub-Sections of Release Bearing and Pedal Adjustment

Section 2 goes from 2-1 to 2-24. The clutch section covers the master cylinder, slave cylinder, release fork, and the entire hydraulic bleed procedure. Toyota specifies a bleed sequence that starts at the slave cylinder and ends at the master—you do that wrong and you will be pumping the pedal for an hour. The manual gives you the free play spec for the pedal: 20–30 mm at the pad. That measurement matters because insufficient free play keeps the throwout bearing in contact with the diaphragm. You will replace bearings twice as often if you ignore that number. It also lists OEM transmission fluid fill quantity in quarts. Imperial units. No metric conversion guess.

Why the OEM Manual Beats Any Aftermarket Reprint

Every aftermarket manual I have touched has at least one torque value that is off. The factory manual for this 1980 Land Cruiser—published by Toyota Motor Corporation, Pub. No. 36044E—has zero tolerance for speculation. The front winch section (Section 10, 62 pages) includes the exact cable tension and drum disassembly steps. The brake section (Section 9, 116 pages) gives you the brake drum diameter wear limit in inches. Aftermarket manuals often mix up the FJ40 and FJ60 rear axle specs. This manual treats each model separately, with a table on page 1-4 that shows how to cross-reference the model code. You want to know which differential carrier fits your BJ40? You look up the model code in the Foreword and then go to Rear Axle & Suspension (Section 7, 41 pages). That is how you avoid ordering the wrong spider gears.

Who Needs This Manual and What Tools You Will Need

This is for the owner who has a 40-series or 60-series Land Cruiser in a garage and wants to do a transmission rebuild or a full steering overhaul. It is for the shop that sees these trucks come in with 200,000 miles and needs the factory specs to do the job in billable time. You will need a torque wrench that reads in ft-lb, a dial indicator for checking axle end play, and a set of SST-like pullers for the steering gear. The manual lists all the special service tools in Section 14. If you own a Toyota Land Cruiser, you need this document in your library. The alternative is calling a dealership and hoping they still have a tech who remembers the FJ40.

Frequently Asked Questions

Does this manual cover the diesel BJ40 models?

Yes. The Foreword lists BJ40, BJ42, BJ43, BJ45, BJ46, and BJ60 series as applicable. The transmission, transfer, axles, steering, brake, and body sections apply to both gasoline and diesel chassis. Engine-specific repair requires separate engine manuals (2F, B series, 2H), which are referenced in the Foreword.

Are the torque specs in imperial units?

All torque values are given in ft-lb. No metric.

You have read the specs. You have seen the page count. This is the same binder that sat on the bench at Toyota dealerships in 1980. Stop using forum printouts. Access the factory manual and keep a copy in your shop tablet. Related manuals: Toyota FJ40 Manual de Serviço (Service Manual), Toyota 2L-T, 3L 1990 Repair Manual – Factory OEM Supplement, Toyota Tercel 1996 Repair Manual – 1202 Page Factory Spec PDF. For more on manual transmissions, see Manual Transmission”> on Wikipedia. For general automotive service best practices, see Automotive Industry Overview”>.