1975–1980 Toyota Land Cruiser FJ40, FJ43, FJ45, FJ55 Repair Manual (P/N 98126)

• 622 PDF pages in two Toyota factory publications — 2F Engine Repair Manual, Pub. No. 98126: 210 pages, ©1974; Land Cruiser Repair Manual — Chassis & Body: 412 pages, ©1977. The chassis/body volume contains model-specific material for FJ40, FJ43, FJ45, FJ55, BJ40, BJ43, and HJ45 series.
• 2F engine tune-up and internal repair — valve-clearance and compression checks, carburetor and ignition adjustment, cylinder-head service, timing-gear and camshaft work, and cylinder-block teardown, inspection, machining-related service, and reassembly.
• Engine support-system overhaul — oil pump and lubrication circuit, water pump and fluid coupling, radiator and thermostat, fuel pump and carburetor circuits, starter performance testing, distributor repair, alternator service, and regulator inspection and adjustment.
• Chassis and driveline procedures — clutch hydraulics and clutch unit, H41/H42 four-speed and J30 three-speed transmissions, transfer case, propeller shaft, semi-floating and full-floating rear axles, front axle, steering knuckle, free-wheel hub, and differentials.
• Steering, brake, winch, frame, and body work — steering gear and wheel alignment; single and tandem master cylinders and boosters; drum- and disc-brake systems; rear and parking brakes; PTO winch overhaul; frame dimensions; and FJ40- and FJ55-series body service.
• Model-specific body electrical coverage — fuse block, ignition and starter switches, lighting, turn and hazard circuits, wipers, combination meter and gauges, front-drive vacuum control, FJ55 tailgate power window, heaters, and six multi-page wiring diagrams.
• Factory workshop reference material — numbered disassembled views with operation-sequence markers, cutaway views, Toyota SST listings and tool numbers, main-component torque tables, lubricants, wear limits, clearances, backlash and preload data, and electrical test specifications.
• Important scope limits — internal engine repair is limited to the 2F gasoline engine. The chassis/body volume also covers BJ40/BJ43 and HJ45 chassis systems, but the B Engine Repair Manual, Pub. No. 98260, and H Engine Repair Manual, Pub. No. 98112, are separate publications. U.S. emission-control devices are assigned to Pub. No. 98117.

2F Engine Repair Depth

The 2F volume is arranged around actual shop operations rather than broad system descriptions. Tune-up coverage includes engine oil and cooling checks, drive-belt and air-cleaner service, battery and spark-plug inspection, high-tension cords, distributor timing, valve-clearance adjustment, carburetor idle and fast-idle settings, throttle-positioner checks, and compression testing.

Internal engine chapters divide the work into cylinder head, timing gear, and cylinder block sections. The cylinder-head material covers valves, springs, rocker arms, and manifolds, with disassembly, inspection and repair, and assembly procedures. Timing-system coverage extends to the valve lifters, camshaft, and gears. The block section goes well beyond gasket replacement, covering pistons and rings, connecting rods, crankshaft and bearings, cylinder boring, camshaft-bearing replacement, input-shaft bearing service, and crankshaft rear oil-seal installation.

The fuel chapter includes carburetor circuit drawings, teardown, inspection, assembly, and adjustment. Starting-system repair includes starter disassembly and a final performance test. Ignition is divided between U.S. and non-U.S. distributor configurations, while the charging chapter distinguishes conventional, heavy-duty, and vacuum-pump alternators and includes on-vehicle inspection and regulator adjustment.

Chassis, Driveline, and Electrical Depth

The chassis/body manual adds the repair work that the engine book does not address. Transmission coverage is split between the H41/H42 four-speed and J30 three-speed units, followed by transfer-case repair. Axle chapters distinguish semi-floating and full-floating rear assemblies and cover differential setup, steering-knuckle and axle-shaft service, free-wheel hubs, bearing preload, and front-wheel alignment. Brake repair is similarly variant-specific, with separate material for single and tandem master cylinders, standard and tandem boosters, vacuum-pump service, drum and disc front brakes, rear brakes, and the parking brake.

Frame dimensions are presented in four model-specific series groups rather than as one generic chart. Body chapters separate FJ55 hood, front and rear doors, windshield, tailgate, and roof-headlining work from FJ40 hood, door, and back-door service. The electrical section then moves through switches, lamps, gauges, wipers, front-drive vacuum controls, heaters, and the FJ55 power-window tailgate.

Six factory wiring diagrams are included: FJ40/FJ43/FJ45, FJ55, HJ45, and BJ40/BJ43 diagrams for markets outside the U.S. and Canada, plus 1975-model FJ40 and FJ55LG diagrams for the U.S. and Canada. Their legends identify wire colors, grid locations for mating connections, and broken-line circuits used for optional equipment or model variations. The North American diagrams are specifically labeled 1975 Model and should not be treated as blanket wiring coverage for every later year.

Factory Tools, Specifications, and Repair Cautions

The SST sections identify the Toyota tools expected for major repair operations, including the 09213-60015 crankshaft pulley and gear puller, 09530-35010 differential drive-pinion adjusting gauge, and 09634-60012 steering-knuckle centering gauge. Specification sections provide standard and component-specific torque tables, engine and service data, transmission and differential preload and backlash information, steering and brake adjustment data, electrical test values, and approved lubricants.

The carburetor chapter warns against cleaning jets or orifices with wire or a drill because the calibrated openings can be enlarged and fuel consumption increased. Front-axle repair depends on keeping knuckle bearings and adjusting shims identified and installing the inner-race and cage assembly in the stated orientation; mixing these parts can upset preload or joint movement. Disc-brake service specifically warns against separating the caliper halves or prying the piston into the bore, where sealing surfaces can be damaged.

Major engine, transmission, axle, and brake work involves heavy assemblies and safety-critical systems. Secure the vehicle on stands rather than a jack alone, support removed assemblies with rated equipment, and isolate the battery before electrical service.