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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.
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