Toyota Chassis and Body workshop and repair manual
Toyota Land Cruiser - Chassis and Body factory workshop and repair manual Covers FJ40,FJ43, FJ45, FJ60, BJ40, BJ 42, BJ43, BJ45, BJ46, BJ60 series and HJ47 and HJ60 series
on PDF can be viewed using PDF reader like adobe , or foxit or nitro
File size 120 Mb Bookmarketed with 851 pages
1980 publication . Does not cover the engine. Covers Clutch, transmission (4 speed H41 and H42 and 3 speed J30),transfer case,propeller shaft, front and rear axles,steering,brakes,winch,frame,body and electrical.
- Safety first (READ BEFORE STARTING)
- Work on a flat, level surface and avoid soft ground.
- Engage parking brake and place wheel chocks on wheels staying on the ground.
- Never rely on the jack alone; always support the vehicle with jack stands.
- Wear gloves and eye protection.
- Tools required (detailed descriptions and how to use each)
- Hydraulic floor jack (or scissor jack that came with the car)
- Description: Lifts the vehicle by pumping handle; floor jack is more stable and easier for a beginner.
- How to use: Position on a flat surface, locate the vehicle jack point (owner’s manual or reinforced pinch welds/solid suspension mounting points), pump handle until wheel is off the ground. Lower by slowly releasing the valve.
- Why required: To lift the vehicle high enough to remove wheels.
- Jack stands (pair, rated for your vehicle weight)
- Description: Adjustable support stands that hold the car after lifting.
- How to use: Place under a solid pinch point or frame once the car is raised, then slowly lower the vehicle onto the stands.
- Why required: Safer than relying on the jack alone.
- Wheel chocks
- Description: Rubber or plastic wedges placed behind/forward of wheels to prevent rolling.
- How to use: Place behind the wheels that remain on the ground (opposite side of the car being lifted).
- Why required: Prevents vehicle movement.
- Lug wrench / breaker bar with correct socket (usually 17mm or 19mm for Toyotas, confirm size)
- Description: Cross-shaped lug wrench or long breaker bar to break loose tight lug nuts.
- How to use: Use before lifting to break initial torque. Apply steady force; use feet/body weight if needed. Avoid sudden jerks.
- Why required: Lug nuts are tightened to high torque and often require leverage to loosen.
- Torque wrench (click-type, ft·lb or Nm scale)
- Description: Tool that measures applied torque; clicks at preset torque.
- How to use: Set to manufacturer’s lug torque spec, snug lug nuts in the pattern, lower wheel to ground, then torque to spec per the sequence until it clicks.
- Why required: To correctly tighten lug nuts—too loose is dangerous; too tight can damage studs.
- Socket set (deep sockets recommended), ratchet
- Description: Assorted sockets to fit lug nuts and other small fasteners.
- How to use: Use with breaker bar or ratchet as needed.
- Why required: For removing lug nuts and any other fasteners.
- Wire brush / rag / brake cleaner
- Description: Wire brush cleans rust/debris from hub; cleaner removes grease.
- How to use: Clean mating surface of wheel and hub to prevent wheel runout.
- Why required: Ensures wheel seats properly; prevents vibration.
- Tire pressure gauge and air compressor (or gas station air)
- Description: Measures and adjusts tire pressure.
- How to use: Check and set pressures to manufacturer spec on placard/owner’s manual.
- Why required: Proper pressure extends tire life and ensures even wear.
- Chalk or a grease pencil and permanent marker
- Description: For marking tire positions and rotation.
- How to use: Mark tire position before moving so you follow the correct pattern.
- Why required: Helps avoid mistakes during rotation.
- Optional but recommended: Torque stick (for impact guns) or impact wrench
- Description: Impact wrench speeds removal/installation; torque sticks limit torque but are less precise than a torque wrench.
- How to use: Remove lug nuts quickly; always finish torque with a torque wrench.
- Why recommended: Saves effort; still verify with a torque wrench.
- Extra tools you might need and why
- Long breaker bar: If lug nuts are seized or very tight.
- Penetrating oil (PB Blaster, WD-40): If studs or lug nuts are corroded.
- Rubber mallet: To tap a stuck wheel free after removing nuts (don’t hit the rotor surface).
- Wheel alignment of intent? Not required for rotation but if you see uneven wear, alignment may be needed.
- Preparation before rotating
- Check owner’s manual for:
- Correct jack points and lug nut torque specification.
- Tire rotation recommendation for your drivetrain (FWD, RWD, AWD).
- Inspect tires for damage, uneven wear, bulges, embedded nails, and tread depth (use a tread depth gauge or coin).
- Note tire direction (directional tread arrows) and whether tires are staggered (different sizes front vs rear).
- Mark current positions on tires (e.g., FL, FR, RL, RR) with chalk/marker.
- Tire rotation patterns (pick the one that matches your car)
- Non-directional, same-size tires on a front-wheel-drive vehicle:
- Forward cross: front tires move to rear on same side; rear tires move to front and cross sides.
- Non-directional, same-size tires on a rear-wheel-drive or 4WD:
- Rearward cross: rear tires move to front on same side; front tires move to rear and cross sides.
- AWD/4WD or when you want evenest wear and all tires are same size:
- X-pattern: all tires move to opposite corners (front left -> rear right, etc.).
- Directional tires:
- Rotate front-to-back on the same side only, do not swap sides.
- Staggered fitment (different front/rear sizes):
- Rotation may not be possible; generally replace only like-for-like positions.
- Step-by-step rotation procedure (concise)
- Loosen lug nuts slightly while vehicle is on the ground (break loose but do not remove).
- Place jack and lift at the recommended jack point until a wheel clears the ground.
- Place jack stand under a solid support point and lower the car onto the stand. Repeat for other side if rotating two wheels at a time.
- Remove lug nuts and wheel. Keep lug nuts together and avoid cross-threading on reinstallation.
- Clean hub mating surface with wire brush and rag. Remove rust/ debris so wheel seats flush.
- Move tires according to chosen pattern and reinstall wheels by hand-threading lug nuts.
- Lower vehicle enough so tires touch ground slightly (or fully lower if you prefer), then tighten lug nuts in a star/cross pattern evenly.
- Final torque to manufacturer spec with torque wrench after vehicle is fully lowered to the ground.
- Check and set tire pressures to the placard values.
- Repeat for all wheels as needed.
- After 25–50 miles (40–80 km), recheck lug nut torque.
- How to use the lug wrench, breaker bar, and torque wrench properly
- Lug wrench/breaker bar:
- Use to loosen nuts while car is on the ground. Apply steady force; use your body weight rather than sudden jerks.
- Torque wrench:
- Set to correct value, use star pattern (for 5-lug use star; for 4-lug use cross). Tighten gradually in sequence until wrench clicks.
- Always torque on the ground; do not torque while on jack stands unless wheel bears full weight.
- Signs that parts may need replacement and what to replace
- Tire replacement (required when):
- Tread depth below 2/32" (legal minimum) or uneven wear (center-only, one-side, cupping).
- Bulges, deep cuts, or visible cords.
- Why: Unsafe, loss of traction, blowout risk.
- Valve stem replacement
- If leaking or rubber looks cracked/old; inexpensive and easy when wheel is off.
- Why: Prevents slow leaks after rotation.
- Lug nuts or wheel studs replacement
- If threads are stripped, studs are damaged, or lug nuts no longer torque correctly.
- Why: Safety—damaged studs can fail.
- TPMS sensors
- If a sensor fails or battery is dead (some die after several years).
- Why: TPMS warnings, inability to read tire pressure.
- Wheel bearings / hub parts
- If you hear grinding or feel play in the wheel before/during removal.
- Why: Safety and handling—replace worn bearings before they fail.
- Brake components (pads/rotor)
- If pads are thin, rotors warped, or you feel pulsation/vibration.
- Why: Rotating tires will not fix brake problems; replace as required.
- Alignment
- If tires show uneven wear after rotation, car pulls, or steering wheel off-center.
- Why: Uneven wear is often a suspension/alignment issue; rotation will not fix alignment.
- Post-rotation checks
- Verify lug nuts torqued to spec.
- Check tire pressures.
- Confirm TPMS has no fault lights; reset/relearn if your vehicle requires it.
- Test drive slowly and listen for unusual noises; recheck lug torque after short drive.
- Quick troubleshooting tips (common beginner issues)
- Stuck wheel: hit the back of the tire with a rubber mallet or use penetrating oil around the hub.
- Seized lug nuts: use longer breaker bar or impact wrench; if rusted, apply penetrating oil and let sit.
- Cross-threaded stud: back off, align, and carefully thread by hand; replace stud if damaged.
- Final safety reminder
- Never get under a car supported only by a jack. Always use rated jack stands on proper support points.
- If you’re unsure about torque specs, jack points, or handling worn parts, consult the owner’s manual or a professional mechanic.
- Typical Toyota lug torque reference (verify in your manual)
- Common range for many Toyota passenger cars: about 76–103 ft·lb (103–140 N·m). Verify for your exact model.
- Done checklist (final quick items)
- Wheels torqued to spec
- Tire pressures correct
- No warning lights
- Visual inspection for new leaks or problems
No unnecessary chat—follow these bullets step by step and replace parts only when signs of damage or wear are present. rteeqp73
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