1980 Toyota Land Cruiser FJ40, FJ43, FJ45, FJ60, BJ40, BJ42, BJ43, BJ45, BJ46, BJ60, HJ47, and HJ60OEM Repair Manual (P/N 36044E)

• Vehicle and publication coverage: Toyota's August 1980 chassis-and-body repair publication, Publication No. 36044E, reproduced as an 851-page PDF for FJ40, FJ43, FJ45, FJ60, BJ40, BJ42, BJ43, BJ45, BJ46, BJ60, HJ47, and HJ60.
• Drivetrain repair: Covers clutch adjustment and bleeding, master/release cylinders, clutch and release-bearing service, H41/H42 four-speed and J30 three-speed removal, teardown, inspection, reassembly, installation, and matching transfer-case overhaul.
• Axles, suspension, and steering: Details propeller shafts, double-Cardan joints, steering knuckles, axle shafts, free-wheel hubs, standard and limited-slip differentials, semi-floating/full-floating rear axles, leaf springs, wheel alignment, steering columns, linkage, manual steering gear, and power steering.
• Brake-system work: Includes tandem master cylinders, booster and vacuum-pump repair, drum and disc brakes, parking and center brakes, the P&B valve, and load-sensing proportioning valve inspection, adjustment, bleeding, and testing.
• Winch, frame, and body sections: Document power takeoff, mechanical and electric front winches, model-specific frame dimensions, hood and door alignment, lift-gate and swing-out door repair, glass and regulator replacement, instrument panel removal, roof, and headlining.
• Electrical and factory reference material: Provides component circuit diagrams, connector and relay/fuse locations, system tests, model/market wiring diagrams, Toyota SST listings, torque tables, service limits, adjustment data, lubricant specifications, and capacities.

Chassis and Drivetrain Documentation

This is Toyota's chassis/body volume, not an internal engine overhaul manual. Toyota directs 2F, B-series, and 2H engine repair to separate publications, so this PDF does not replace the correct engine book.

The transmission chapters are organized around the actual hardware. H41 and H42 four-speed procedures are kept separate from J30 three-speed work, with cutaway views and coverage of the gear case, case cover, synchronizers, shift forks, bearings, seals, shaft clearances, reassembly, installation, and final shifting checks. The transfer chapters follow the same configuration split rather than combining unlike assemblies.

Axle and steering coverage is equally specific. Front-axle procedures address knuckle and axle-shaft repair, hub-bearing adjustment, free-wheel hubs, differential service, springs, stabilizer bar, shocks, and alignment. Rear-axle sections distinguish semi-floating from full-floating designs and cover standard and limited-slip differential setup, including preload, backlash, shim selection, and inspection limits. Steering material separates tilt and standard columns, 4-series and 6-series gear arrangements, linkage repair, and power-steering pump and gear-housing diagnosis, bleeding, pressure testing, and overhaul.

Brake, Body, and Electrical Coverage

The brake chapter identifies drum- and disc-brake configurations, tandem master cylinders, Aisin and JKC booster arrangements, vacuum-pump service, rear brakes, parking/center brakes, the proportioning-and-bypass valve, and the load-sensing proportioning valve. Procedures cover removal, disassembly, inspection, assembly, installation, adjustment, bleeding, and on-vehicle checks.

Body and frame information is divided by vehicle family. Frame-dimension drawings are provided for the 60-series chassis and for FJ40/BJ40-42, FJ43/BJ43-46, and FJ45/BJ45/HJ47 groups. Separate 4-series and 6-series body material covers hinges, locks, doors, lift gates, swing-out doors, regulators, glass, strikers, the instrument panel, roof, and headlining. Numbered component views show assembly relationships and alignment points used during repair.

The body-electrical section includes circuit diagrams and inspection procedures for ignition and combination switches, lighting, turn/hazard systems, front and rear wipers/washers, headlight cleaner, gauges, warning systems, rear defogger, heater, and radio/stereo. The wiring appendix is configuration-specific: it contains 1981-production diagrams for BJ40/BJ43/HJ47, FJ40/FJ43, BJ60/HJ60, and FJ60 groups, plus separate USA/Canada sheets for FJ40, BJ40, FJ60, and BJ60. Left- and right-hand drive layouts, market equipment, and 12- or 24-volt systems are identified where applicable.

Representative factory illustrations include the H41/H42 transmission-and-transfer cutaway, front-axle and steering-knuckle views, tandem master-cylinder and brake-booster cutaways, the mechanical-winch power train, bulkhead-connector inspection views, and the model-specific 1981 wiring sheets.

Specification and Assembly Data

Toyota lists special service tools by illustration, name, and tool number. Examples include SST 09301-00012 for the diaphragm aligner set, 09301-20020/09301-55022 clutch guide tools, and 09303-35011 for the input-shaft front-bearing puller. Further SST tables cover transmission, transfer, propeller shafts, axles, steering, brakes, winches, and body work.

The final tables consolidate component-specific torque specifications, transmission and transfer clearances, bearing preload, differential backlash and shim data, steering limits, brake wear limits, winch checks, approved lubricants, and fluid capacities.

Factory cautions also flag real repair traps. The steering section treats the worm-and-ball-nut assembly as non-serviceable and warns against running the ball nut into the worm ends because the recirculating balls can be damaged. The electrical section explains that probing the receptacle side of a bulkhead connector can spread its terminals and create poor contact. Use rated stands and lifting equipment for transmission/transfer, axle, and winch assemblies, and complete the specified brake and steering checks before returning the vehicle to service.