Toyota A442F Automatic Transmission factory workshop and repair manual
Toyota A442F Automatic Transmission factory workshop and repair manual
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Covers
Operation
Component Parts Removal
Oil Pump
Overdrive Unit
Front Clutch
Rear Clutch
Second Brake
Front and Rear Planetary Gear Unit
First and Reverse Brake
Valve Body
Upper Valve Body
Lower Valve Body
Transmission Case
Parking Lock Pawl
Component Parts Installation
Service Specifications
A442F Automatic Transmission repair and workshop manual Covers FZJ80 and HDJ80 Toyota Landcruiser, Hardtop, canvas top, station wagon Covers the 4 speed electronic controlled The new A442F automatic transmission is a 4 —speed Electronic Controlled Automatic Trans- mission and has following features;
Electronic control provides the Automatic Transmission shift and lockup points most appropriate for the power characteristics of each engine and improves shift response.A high performance super flow torque converter in the Automatic Transmission is used to improve starting off, acceleration and fuel economy.For easier operation, the transmission shift lever positions have been reduced from 7 (P,R,N,D,3,2,L) to the 6 positions (P,R,N,D,2,L) used in Landcruiser vehicles, and an overdrive main switch has been provided on the shift lever.On vehicles using the 1FZ —FE engine, shift response has been greathly improved by communication between the Engine ECU and ECT ECU to momentarily reduce engine output when shifting.
Toyota A442F Automatic Transmission factory workshop and repair manual
Tools & consumables
- Metric socket set (8–19 mm), deep sockets recommended
- Ratchet, 3/8" and 1/2" drive, 6" extension, universal joint
- Torque wrench (range to ~100 ft·lb / 135 N·m)
- Breaker bar
- Box/combination wrenches (10, 12, 14, 17 mm typical)
- Screwdrivers, small prybar
- Jack, jack stands (or vehicle lift)
- Wheel chocks
- Penetrating oil (PB Blaster, etc.)
- Wire brush / terminal cleaner
- Multimeter
- Shop rags, gloves, eye protection
- Replacement starter motor (correct part for your Toyota/A442F application)
- Replacement mounting bolts or terminal nuts (if corroded)
- Dielectric grease or anti-corrosion spray
- Optional: small pick, heat shield if fitted, battery terminal puller
Safety first
- Work on level ground. Chock wheels and set parking brake. Put vehicle in Park.
- Disconnect negative battery terminal and tape it aside before touching any electrical parts.
- Support vehicle securely on jack stands — never rely on a jack alone.
- Wear eye protection and gloves. Avoid metal tools bridging battery positive to chassis.
- If working under the engine/trans, ensure good lighting and a safe escape path.
Overview (what you’ll do)
1) Disconnect battery and prepare vehicle access.
2) Raise and support vehicle; remove any obstructing parts (splash shields, heat shields, crossmember if necessary).
3) Disconnect starter wiring and remove starter mounting bolts.
4) Remove old starter, compare to new unit, install new starter, reconnect wiring, torque bolts to spec, test.
Step-by-step procedure
1. Prep
- Park, chock, set parking brake. Put trans in Park.
- Disconnect the negative battery cable first. Secure it away from the battery.
2. Access
- Raise the front of the vehicle and safely support on jack stands (or use a lift).
- Locate the starter: on A442F-equipped Toyotas the starter is mounted at the bellhousing area (lower engine/transmission junction), usually accessible from below or from the passenger-side wheel well.
- Remove any splash shield, plastic covers or heat shield blocking access. Loosen exhaust or crossmember only if necessary for clearance.
3. Inspect & prepare
- Use a multimeter to verify battery voltage (≥12.4 V recommended for reliable cranking).
- Spray penetrating oil on starter mounting bolts and allow time to seep in if rusty.
4. Disconnect electrical
- Identify large battery cable on the starter solenoid (big stud with nut) and the small control wire (solenoid activation lead).
- Remove the small wire first (usually held by a small nut or push-on connector). Then remove the main battery cable nut and lift the cable off. Protect the cable end so it doesn’t touch chassis while you work.
- Note and/or photograph wiring locations so reinstallation is correct.
5. Remove mounting bolts
- Support the starter with one hand or a jack under it. Remove the starter mounting bolts (typically 2 or 3). Use a suitable socket, extension and universal joint for tight access.
- Be prepared for seized/rounded bolts — use penetrating oil and breaker bar. If a bolt breaks, cut or drill carefully; common pitfall: rounding bolt heads. Use correct socket size and firm, steady force.
6. Remove starter
- Lower the starter from its position and remove it. Inspect the starter mounting face, bellhousing, and flywheel ring gear teeth that are visible for damage or heavy wear.
7. Compare parts
- Compare old starter to new unit: same mounting pattern, pinion type, electrical studs and clearance. Check that the pinion engages the flywheel smoothly and the solenoid is on the correct side.
8. Install new starter
- Clean mating surface on bellhousing with wire brush; remove corrosion so starter seats flush.
- Position new starter into place. Start the mounting bolts by hand to avoid cross-threading.
- Tighten bolts snugly, then torque to manufacturer spec. If you don’t have the spec, tighten evenly and use a torque wrench to a typical range (commonly 35–60 ft·lb / 47–81 N·m for starter bolts — consult service manual for exact value for your model).
- Reattach main battery cable to the large stud and small control wire to the solenoid terminal. Use new terminal nuts if original are corroded. Clean terminals, apply dielectric grease to prevent corrosion.
9. Reinstall removed parts
- Reinstall any heat shields, splash panels, or crossmember components removed for access. Ensure all fasteners are tightened.
10. Test
- Reconnect negative battery terminal.
- With vehicle still supported and in Park/neutral safety satisfied, attempt to start. Listen for smooth engagement and no unusual grinding.
- Use the multimeter to check for proper voltage drop under cranking if diagnosing starter draw issues (acceptable voltage at starter while cranking typically above ~9–10 V; low voltage indicates battery/cable issue).
How the tools are used (practical tips)
- Ratchet, extensions and universal joint: allow access to tight mounting bolts behind crossmembers. Use deep sockets on long studs.
- Breaker bar: to initially break loose seized bolts. Use steady force—avoid sudden jerks that round heads.
- Torque wrench: final torque on mounting bolts and battery terminal nuts prevents loosening and over‑tightening damage.
- Penetrating oil: apply and let soak if bolts are rusty—apply heat only if you know how and use caution.
- Multimeter: confirm battery voltage and test post-install voltage drop.
- Wire brush: clean mounting face and battery cable ends for good electrical contact.
Replacement parts and consumables recommended
- Complete replacement starter motor (OEM or quality aftermarket specific to vehicle & A442F application)
- New mounting bolts or at least clean/reusable bolts; replace if threads or heads are corroded
- New terminal nuts and small insulators if damaged
- Battery cable or ring terminal ends if corroded
- Dielectric grease and thread locker only where specified by OEM (generally not on starter bolts unless specified)
Common pitfalls and how to avoid them
- Not disconnecting battery first — risk of shorting and injury. Always disconnect negative before touching starter wires.
- Rounding bolt heads — use proper socket size, penetrating oil, and steady force. Have an extractor kit ready.
- Incorrect wiring on reinstallation — take photos before removal; confirm the big battery cable goes to the big stud and small wire to the solenoid trigger.
- Reusing badly corroded terminals — leads to high resistance and poor cranking, so replace/clean terminals.
- Not torquing bolts to spec — causes misalignment or loosening; hand-tight is not enough.
- Wrong starter unit — ensure the replacement matches mounting pattern, pinion type and electrical connections for the A442F bellhousing.
- Ignoring flywheel damage — starting with a damaged ring gear will destroy a new starter quickly. Inspect teeth.
- Forgetting to secure battery cable away from the starter during install — it can short to chassis during work.
Estimated time
- 1–2 hours on a lift; 2–4 hours in tight under-vehicle spaces or if bolts are seized.
Final checks
- After a successful start, test under load (headlights on) and listen for unusual noises. Recheck torque on mounting bolts after a short test drive.
Done. rteeqp73
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- Safety first (read once, follow exactly)
- Wear safety glasses and gloves; have a fire extinguisher nearby.
- Work on a flat level surface, chock wheels, block the driveline (put in park and set parking brake).
- Never rely on a jack alone — use rated jack stands under proper frame points. Transmission removal requires a transmission jack or a very secure floor jack and cribbing.
- If you are unsure at any point, stop and get professional help — automatic transmissions are heavy, spring-loaded, and can cause severe injury.
- Quick overview of the problem and approach
- “Overdrive repair” usually means diagnosing why the transmission will not enter or hold 4th (overdrive): common causes are low or burnt fluid, faulty overdrive switch/solenoid/electrical problem, clogged filter/valve body, or worn internal clutches/bands.
- Start with simple, safe checks (fluid, wiring, codes), then move to filter/pan service, then solenoid/valve-body work. Internal clutch/band repairs or full rebuilds are advanced and may require a transmission shop.
- Basic tools you should have (descriptions and how to use)
- Socket set (3/8" and 1/2" drive; metric and standard sockets): used to remove pan bolts, crossmember, transmission-to-engine bolts. Choose the correct-size socket, fit fully on the fastener, and pull steadily to avoid rounding heads.
- Ratchet and extensions: ratchet for turning sockets; extensions help reach recessed bolts.
- Breaker bar: long non-ratcheting bar for breaking loose stubborn bolts; apply steady force, not sudden jerks.
- Torque wrench (click-type): set to specified torque and tighten bolts to spec to avoid leaks or stripped threads. Use in final tightening only.
- Combination wrench set: for places a socket can’t reach.
- Flathead and Phillips screwdrivers: prying clips or removing small screws; use the correct size to avoid cam-out.
- Drain pan (large capacity, shallow): catch ATF when pan is removed — ATF volume can be several liters/quarts.
- Funnel: for refilling transmission fluid at the dipstick tube or fill port.
- Jack and rated jack stands: jack to lift vehicle; stands to support it securely. Position stands on unibody/frame lift points.
- Wheel chocks: prevent vehicle roll.
- Shop rags and absorbent pads: clean up spills; used fluid is slippery and flammable.
- Gloves and safety glasses: protect your hands and eyes from hot fluid and debris.
- Gasket scraper or plastic putty knife: remove old gasket material from pan and mating surfaces; avoid gouging surfaces.
- Rubber mallet: to tap pan loose if stuck; avoid metal hammering on pan.
- Magnet (or check pan magnets): many pans have magnets to collect metal flakes.
- Creeper or padded mat: to move under vehicle safely.
- Diagnostic electronics and measurement tools (why you might need them)
- OBD-II scanner (with transmission code support): reads trouble codes (e.g., solenoid circuits, torque converter circuit). Plug into diagnostic port; follow scanner prompts to view transmission-related codes. If code found, Google or a manual explains what that code means for transmission components.
- Multimeter (digital): to check continuity and resistance of switches, solenoids and wiring. Set to ohms for resistance checks; back-probe connectors or unplug and probe pins; compare to spec (service manual).
- Test light: quick check for power/ground at connector pins.
- Line pressure gauge and adapter (advanced): measures internal pressure — necessary for in-depth diagnosis of valve body/pressure problems. Requires going through service-procedure steps and is advanced.
- Transmission jack or heavy-duty floor jack and a wooden cradle (if removing the transmission): used to support and lower the transmission safely during removal.
- Extra specialized tools you may need for deeper work (and why)
- Valve body gasket kit and valve body bolt torque specs: valve body removal requires careful reassembly; gaskets must be replaced to avoid leaks.
- Solenoid/replaceable solenoid pack (matched to A442F): the solenoids control hydraulic circuits for overdrive; testing and replacement may fix OD engagement issues.
- Seal driver / bearing puller / snap-ring pliers / circlip tools: for removing internal components during rebuild.
- Press or shop with a hydraulic press (for clutch packs or bushing replacement) — these jobs are not a good DIY unless experienced.
- Full service manual or OEM repair manual (Haynes is helpful but less detailed than OEM): gives torque specs, fluid type, dipstick procedure, wiring diagrams and disassembly order. This is essential.
- Preliminary checks (do these first)
- Check fluid level and condition
- Warm the engine to normal operating temperature (drive gently to warm up).
- With engine idling and parking brake set on level ground, pull the transmission dipstick (if equipped) and check level and color/smell.
- Healthy fluid: red/translucent, not dark brown/black, no strong burnt smell, no large metal flakes.
- Low fluid or contaminated/burnt fluid -> can cause OD problems; correct level first and inspect for leaks.
- Check for external leaks
- Inspect pan gasket, cooler lines, transmission pan bolts, axle seals and rear extension housing for wetness.
- Tighten loose pan bolts to spec; replace pan gasket if leaking.
- Read codes and inspect wiring
- Use OBD-II scanner to check for transmission-related codes; note codes and look them up.
- Visually inspect wiring to the overdrive switch/solenoids for broken wires, corrosion, or poor connectors.
- Use a multimeter to verify power and ground at the OD switch/solenoid connectors.
- Fluid and filter service (common beginner fix and highly recommended)
- Why it helps
- Dirty fluid or a clogged filter/strainer can prevent hydraulic pressure from building to engage overdrive; changing fluid and filter often fixes shift/OD issues.
- Step-by-step (high level)
- Warm vehicle, raise and support securely with jack stands.
- Place drain pan under transmission pan.
- Loosen pan bolts (leave one corner threaded initially) and let fluid drain; or remove drain plug if equipped.
- Remove pan, collect fluid, remove filter (usually held by bolts or a clip), inspect pan magnets for metal debris, scrape old gasket off mating surfaces.
- Install new filter (use OEM or quality aftermarket), install new pan gasket (or use RTV where specified), reinstall pan and torque bolts to spec.
- Refill with manufacturer-specified ATF to the dipstick level (do not overfill). Start engine, cycle through PRND and gears, recheck level per manual procedure.
- Dispose of used ATF responsibly.
- Tools used and how:
- Socket set + ratchet: remove pan bolts; use extension where needed.
- Drain pan: catch fluid.
- Gasket scraper: remove old gasket—work gently.
- Torque wrench: tighten pan bolts to spec—do final tightening in a crisscross pattern.
- Funnel: refill.
- Overdrive switch and wiring check (easy, low-cost)
- Locate the OD switch (usually on tail housing) and visually inspect it and plug.
- Use multimeter to check continuity when switch activated (refer to manual for pinout). Check for 12V supply and ground at connector with key on.
- Replace switch if defective; replacement is inexpensive and simple: unplug connector, unscrew old switch, screw in new one. Use thread sealant if required by manual.
- Solenoid and valve body diagnosis (intermediate)
- Symptoms of solenoid/valve body problems: no OD engage, harsh or late shifts, codes for solenoid circuits.
- Test solenoids electrically with a multimeter (resistance values specific to solenoid type; check service manual).
- If solenoids fail, replace them or the solenoid pack. Use OEM or quality parts.
- Cleaning the valve body and screen can remove contamination; removal requires careful documentation of bolt locations and spring/plate placement — take plenty of photos and tag parts. Reassemble exactly in order; use new gaskets.
- Tools used:
- Multimeter: resistance tests.
- Socket set, torque wrench: remove and reinstall valve body.
- Clean shop solvent and lint-free wipes: clean passages.
- Note: valve body work is trickier than pan/filter work; if uncomfortable, have a transmission specialist do it.
- When internal parts must be replaced (what to look for and why)
- Metal flakes in pan, lots of friction material on magnets, burnt fluid smell, or slipping that doesn’t improve after fluid/filter/solenoid replacement: likely internal clutch pack, band, or servo damage.
- Typical replaceable internal parts:
- Overdrive clutch pack (clutch discs and steels)
- Return springs and band components
- Servos and seals
- Seals and gaskets throughout the transmission
- Torque converter (if TCC or bearings damaged)
- Why replacement is required: friction material wears or burns, hydraulic seals harden, and valve bores wear; these prevent correct hydraulic pressure, causing slippage and loss of OD.
- Major internal work requires a rebuild kit, specialty tools (presses, drivers), and often a clean shop environment — many beginners choose a remanufactured transmission or professional rebuild instead of DIY rebuild.
- Parts you will commonly need for OD problems on an A442F (buy OEM or quality aftermarket)
- Transmission filter (service kit)
- Pan gasket (or RTV gasket sealant if service manual specifies)
- Correct ATF type (use the Toyota-specified ATF listed in the manual)
- Overdrive switch (tailshaft switch)
- Solenoid(s) or solenoid pack (if electrically failed)
- Valve body gasket(s) and seals (if valve body removed)
- Pan bolts (if corroded or heads rounded)
- Rebuild parts (clutch packs, seals, servos) only if internal wear found
- Final checks and road test
- After fluid/filter/parts replacement: start engine, check for leaks, ensure gear selector moves correctly, allow the transmission to warm up, then go for a controlled road test.
- Verify OD engagement under normal driving conditions. If still not engaging, note behavior (hard shift, slipping, codes) — this info helps narrow the fault.
- When to stop and go to a pro
- If you find metal shavings, burnt fluid, repeated slipping after fluid/filter change, failed internal tests, or you need to remove the transmission: take it to a transmission shop. Rebuilding and precise valve-body work without the right tools/experience can permanently damage the unit.
- Short checklist of likely first actions for a beginner
- Check fluid level/condition and top if low.
- Scan for transmission codes.
- Inspect OD switch wiring and connector; test/replace switch if needed.
- Do a fluid + filter + pan gasket service.
- If problem persists, test solenoids and consider valve body service or professional help.
- Parts & consumables to buy before starting
- OEM filter + pan gasket kit
- Correct quantity and type of ATF (check manual)
- New OD switch (optional inexpensive spare)
- Replacement solenoids (if codes or failed tests)
- Rags, gloves, a large drain pan, and a disposal container for used ATF
- Final practical tips (no fluff)
- Take labeled photos during disassembly so reassembly is exact.
- Work methodically and keep fasteners organized by location.
- Use the factory service manual for torque specs and procedures — it’s essential.
- Expect fluid/filter change to solve many OD problems; internal repairs are a next step and often costly.
No questions asked — follow above in order: check fluid and codes, inspect OD switch/wiring, do filter/pan service, then pursue solenoids/valve body; move to a professional for internal rebuilds or if you don’t have a transmission jack and shop equipment. rteeqp73