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
Below is a focused, practical guide to overhauling the gearset (planetary/drive components) of a Toyota A442F automatic transmission aimed at a beginner mechanic. It covers why and when this is needed, how the system works, every major component and its function, step‑by‑step disassembly/inspection/reassembly guidance, what commonly fails, tools/consumables, and safety notes. I do not give specific torque or clearance numbers — always follow the Toyota factory service manual for exact specs and tolerances.
Summary / Theory first (short)
- An automatic transmission uses a torque converter and a set of planetary gearsets, controlled by hydraulic clutches and servos, to produce different output ratios. The gearset is the mechanical heart: sun gear(s), planet pinions & carriers, ring gear(s), clutches/drums and one‑way clutches. Clutches and bands selectively hold or drive parts of the planetary sets so the transmission produces 1st, 2nd, 3rd, 4th and reverse.
- Overhaul of the gearset is needed when mechanical wear (worn clutch packs, scored drums, worn bushings/bearings, damaged planets/sun/ring gear teeth, failed sprags) causes slipping, harsh shifts, burned fluid, metal debris in pan, low pressure, or abnormal noises. Think of it like rebuilding a multi‑speed bicycle hub that uses brakes to lock parts of the hub to get different gear ratios — when the brakes or bearings wear, the hub won’t shift or will slip.
Components (what they are and what they do)
- Torque Converter: hydraulic coupling/transmission input. Contains pump (impeller), turbine, stator (with a one‑way sprag), and lockup clutch (if equipped). Transfers engine torque into the transmission.
- Oil Pump (transmission pump/front pump): driven by the input; generates hydraulic pressure to operate clutches/valves. Comprised of housing, rotor, and vanes.
- Planetary Gearsets: the core gear trains. Each gearset contains:
- Sun gear: center gear.
- Planet gears/pinions: gears that orbit the sun and ride in the carrier; mounted on pinion shafts or bearings.
- Planet carrier: holds the planets and transfers torque out to shafts.
- Ring gear (annulus): outer gear with internal teeth.
- These three elements (sun, planets/carrier, ring) are selectively held or driven to produce gear ratios.
- Clutch Packs (multiple packs): alternating friction plates (linings) and steel plates inside drums. When hydraulic pressure compresses the pack, the drum is locked to the hub or carrier, making that element driven.
- Drums/Direct Drum/Overdrive Drum: housings that contain the clutch packs.
- Bands and Servo: steel bands wrap drums and are actuated by servos to hold a drum/element stationary in some ratios.
- One‑Way Clutch / Sprag: allows rotation in one direction only; used for smooth engagement and to prevent backdrive.
- Thrust Washers, Bushings, Needle Bearings: provide clearances and reduce friction between rotating parts.
- Output Shaft & Final Drive: transmits torque to driveshaft/differential.
- Valve Body: hydraulic control center with valves & passages; directs oil to clutches/servos. (Important, but if your focus is the gearset, check it for contamination.)
- Seals, O‑rings, Gaskets, Filter: keep fluid contained and clean.
Analogy: Planetaries are like the inner workings of a mechanical planetarium. The sun is the sun, planets rotate around it; hold the ring still, spin the sun, and the planets carry the carrier at a different speed. Clutch packs are like band brakes that lock parts of that miniature solar system to change how fast the carrier turns.
Tools & consumables (minimum)
- Full size tool set: sockets, wrenches (including 1/2" drive ratchet), torque wrench (proper range).
- Snap‑ring pliers (internal + external).
- Bearing puller or press, drift set and seal drivers, soft/nylon hammer.
- Dial indicator (to measure endplay), calipers/micrometer, feeler gauges, plastigage for clearances.
- Transmission jack or floor jack + trans support, engine support if needed.
- Clean workbench, trays for parts, marker/labels, camera for reference.
- Clean lint‑free rags, solvent/brake cleaner, parts washer (if available).
- New gasket set, seal kit, rebuilt clutch packs or friction plates, new thrust washers/bushings/bearings as needed, new snap rings. Replace any worn sun, planet, ring teeth or carrier.
- Transmission assembly lube (or recommended ATF) and correct ATF per factory spec.
- New filter, pan gasket, and torque converter seals. Torque converter fluid fill per manual.
- Shop manual for Toyota A442F (required).
Safety
- Use a transmission jack — do not rely on a floor jack unsupported.
- Drain ATF carefully; avoid skin/eye contact and inhalation. Wear gloves and eye protection.
- Keep workspace clean — contamination kills clutches and bearings.
- Label and photograph everything during disassembly for reassembly.
High‑level overhaul procedure (logical order)
Note: This is a condensed but detailed flow. Follow the shop manual for bolt torque, clearances and any model‑specific sequence.
1) Prep and removal from vehicle
- Warm up vehicle slightly to reduce fluid viscosity. Park, set parking brake, disconnect battery.
- Drain ATF from transmission pan. Remove pan, inspect magnet for metal particles — save for later analysis. Remove filter.
- Disconnect linkage, cooler lines, speedometer cable/gear, electrical connectors, starter, driveshaft(s). If transfer case is attached, remove transfer case or disconnect as required.
- Remove torque converter bolts (from flexplate) after supporting converter; rotate engine to access bolts. Mark converter to input shaft orientation if needed.
- Unbolt bellhousing to engine, lower transmission with jack. Inspect bellhousing and flexplate.
2) Bench disassembly to access gearset
- Secure transmission on bench. Remove torque converter (careful — may contain fluid).
- Remove front pump housing if required to reach front planetary assembly. Inspect pump rotor/casing for scoring and measure clearances (replace pump if runout or scoring beyond spec).
- Remove output housing/pan/accumulators/drums as needed to expose the clutch drums and planetary carrier.
- Remove snap rings, servo covers, and shift valve bodies that mechanically lock gearset components.
- Remove drums/clutch packs one at a time. Keep clutch stacks and steels in order. Photograph layers. Look for burnt/discolored plates and glazing.
- Remove planetary carrier(s): unbolt and slide out carrier assembly(s) with planets and pinions. If carrier is staked, remove staked retainer carefully or tap out pins as specified.
- Remove sun gear(s), ring gear if necessary, output shaft and intermediate shafts.
3) Clean and detailed inspection (critical)
- Clean every part with solvent/parts washer. Use compressed air to dry. Do not use high‑pressure air on seals.
- Clutches: measure friction lining thickness; check steels for heat spots/warpage. Replace any clutch packs with worn/burned linings or steel distortion.
- Drums: inspect bores for scoring, ridges where plates ride. If deep grooves exist, replace or have drums reconditioned.
- Planet gears/sun/ring: inspect teeth for pitting, chips, or heavy wear. Replace any damaged gears.
- Bearings/bushings/needle bearings: check for wear, flat spots, or looseness in bores. Excess radial play → replace bushing or bearing. Look for copper or bronze flakes in fluid (sign of bushing failure).
- Thrust washers: check for excessive wear or scoring; these set endplay. Replace if worn beyond spec.
- Snap rings/retaining rings: check for deformation — they must hold axially.
- One‑way clutches/sprags: inspect sprag surfaces for wear or slipping. A failed sprag often causes 2nd‑gear slip or flare.
- Pump: check rotor/tip clearance; an excessive clearance causes low line pressure. Replace worn pump parts.
- Torque converter: inspect turbine/stator/impeller and clutch (if external) for damage. If stator sprag has failed, torque converter must be replaced or rebuilt.
4) Replace worn parts
- Replace clutch packs, steels, all seals and gaskets, thrust washers, bushings, bearings, and any gears showing wear. Replace filter and pan gasket.
- If wear is localized (e.g., one drum is scored), replace drum or have it machined per spec. Don’t mix old friction plates with new steels — replace full sets.
5) Reassembly of gearset (order & key points)
- Cleanliness: every surface must be oil‑clean and free of debris.
- Lubrication: soak friction plates in ATF (some recommend an hour) and coat bearings/bushings with assembly lube.
- Install sun gear(s) and thrust washers into carrier per manual orientation.
- Reassemble planet pinions into carrier with proper clips/pins; ensure correct needle bearings orientation.
- Install carrier into case; set correct axial endplay using new thrust washers or as manual requires. Check endplay with a dial indicator.
- Reinstall clutches into drums in the exact order removed. Make sure the friction plates seat properly on splines and steels are not reversed. Confirm free movement before final assembly.
- Install one‑way clutch/sprag with attention to orientation — sprags are directional.
- Reinstall drums and snap rings, then servo/band assemblies. Adjust band clearances per manual if adjustable.
- Reinstall front pump (if removed). Check pump rotor endplay and lateral clearances — use plastigauge if needed or measure per manual. Replace pump if excessively worn.
- Torque all bolts to spec, stake or safety any critical fasteners as required by manual.
- Reinstall valve body and torque to spec; replace all gaskets and O‑rings. Reattach solenoids and connectors.
6) Torque converter preparation and installation
- Fill torque converter with ATF until full (so fluid flows from the hub or per manual). This avoids running pump dry on first start.
- Slide torque converter onto input shaft; it must fully engage and seat with proper spline engagement. There is usually visible engagement — count spline turns or note a stop.
- Reinstall transmission to engine, torque bellhousing bolts per spec, reconnect flexplate converter bolts and torque to spec.
7) Fluid, initial run and adjustment
- Refill with the correct type and approximate quantity of ATF per manual. Don’t overfill.
- Start engine and allow to reach operating temperature. Cycle through gears with brake applied (park -> drive -> reverse, etc.) to seat clutches/accumulators and move fluid.
- Check for leaks. Re-check ATF level at correct temperature and on level ground.
- Road test carefully. Check shift quality, noises, and temperature. After short break‑in drive, recheck fluid level.
What to measure / critical checks (and why)
- Clutch friction thickness and steel flatness: thin/bent plates cause slip or shudder.
- Drum bore dimensions and spline wear: excessive wear causes clutch packs to not engage fully → slip.
- Endplay (axial) of carriers and shafts: too much endplay causes harsh shifts; too LITTLE causes binding and premature wear.
- Pump rotor clearance: too loose → low pressure & slip; too tight → seizure.
- One‑way clutch operation: if it fails, certain gear engagements flare or not hold.
- Valve body cleanliness: debris will cause stuck valves and wrong shift timing/harshness.
Common failure symptoms & likely causes
- Slipping in 1st/2nd/3rd: worn clutch packs, burnt friction material, steel warpage, low hydraulic pressure (pump).
- Harsh or delayed shifts: worn clutches, defective accumulators, wrong band adjustment or valve body problems.
- Shudder or vibration under steady throttle: worn torque converter lockup clutch (if equipped) or contaminated/burnt clutches.
- No forward drive but reverse OK: failed direct clutch/one‑way sprag or specific planetary component failure.
- Metallic debris in pan or on magnet: internal wear — typically bushings, sun/planet pinions, or clutch steel fragments — do not reuse if heavy metal present.
- Whine or groan: pump wear or bearing failure.
- Fluid overheating / burnt smell: slipping clutches, incorrect fluid, or poor cooling.
Practical tips and traps (from experience)
- Photograph every step and label stacks of clutch plates; mixing order will cause trouble.
- Replace clutch packs in complete sets. Do not mix old and new.
- Never reuse seals, O‑rings, or paper gaskets.
- Use assembly lube or ATF on components during assembly; dry surfaces will wear fast on first start.
- If you’re unsure about a bushing/bearing condition, replace it — these are cheap insurance versus tearing down again.
- Do not over‑tighten snap rings — they must seat in their groove fully. If a snap ring is sprung or deformed, replace it.
- If you find broken teeth or a severely worn planet/sun, replace the entire gearset or carrier as partial repairs often fail.
- If pump rotor/casing is scored, replace pump; low line pressure ruins clutches fast.
- After rebuild, use only the recommended ATF type and change fluid again after the initial break‑in (per manual).
Why this repair is needed (rephrase)
- The gearset rebuild addresses mechanical wear that hydraulic control alone cannot fix. Slippage, loss of drive, grinding/noise or metal debris all point to worn mechanical components (clutches, drums, gears, bushings). Replacing only the pan/filter or valve body will not cure mechanical wear inside the planetary and clutch assemblies.
Closing — final checklist before reinstallation
- All parts cleaned and inspected; replaced wear items installed.
- New seals/gaskets/filter in place.
- Torque converter pre‑filled and installed correctly.
- Pump and valve body checked and torqued to spec.
- Endplay and clearances measured and documented to manual specs.
- Fluid filled with recommended ATF, initial checks done, and road test planned.
If anything is unclear or you need the factory torque/clearance specs for specific components (endplay, clutch thickness limits, pump clearances), consult the Toyota A442F service manual for your vehicle year and model — those numbers are required to finish accurately. rteeqp73
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Interpreting your request as work on the transmission “pressure regulator” (line pressure / pressure control valve) inside a Toyota A442F automatic transmission. Below are step‑by‑step instructions, every tool explained and how to use it, and guidance on parts — concise and practical for a beginner. Safety first.
Safety and preparation
- Wear safety glasses and nitrile or mechanic’s gloves to protect eyes and skin from hot fluid and dirt.
- Work on a flat level surface, parking brake on, engine cool. Use wheel chocks on the wheels remaining on the ground.
- Disconnect the negative battery terminal if you will be working near wiring or sensors.
- Have absorbent pads and a drain pan ready for ATF — transmission fluid is slippery and hot if the vehicle was recently driven.
Tools required (each tool explained and how to use it)
- Floor jack
- Purpose: raise the vehicle to access the transmission pan/valve body.
- How to use: position on a reinforced pinch-weld or jack point, pump handle to lift vehicle until clearance for jack stands is reached. Never rely on the jack alone.
- Jack stands (pair)
- Purpose: safely support the vehicle while you work underneath.
- How to use: set to the same height and place under sturdy frame points; slowly lower the vehicle onto the stands.
- Wheel chocks
- Purpose: prevent rolling.
- How to use: place behind wheels that remain on the ground.
- Drain pan (large, shallow)
- Purpose: catch ATF when you drop the pan or open drain.
- How to use: position under transmission pan; have rags ready for spills.
- Set of metric sockets (deep and shallow, 8–19 mm commonly)
- Purpose: remove pan bolts, valve body bolts, and other fasteners.
- How to use: match socket size to bolt head; use correct socket depth so you don’t round bolts.
- Ratchet and extensions (1/4” and/or 3/8” drive)
- Purpose: turn sockets in confined spaces.
- How to use: attach socket, use extension to reach recessed bolts; keep steady force.
- Torque wrench (3/8” drive, range to at least 80 ft·lbs)
- Purpose: tighten bolts to correct torque to avoid leaks or damaged parts.
- How to use: set the required torque (consult service manual for values), tighten slowly until it clicks; snug in a star/sequence when specified.
- Screwdrivers (flat and Phillips)
- Purpose: remove clips, pry small parts, assist with pan gasket removal.
- How to use: use correct tip size to avoid stripping heads; use flat screwdriver carefully to pry.
- Small pick set and magnet pickup tool
- Purpose: remove seals, retrieve small parts/balls/springs from valve body.
- How to use: use picks to dislodge O‑rings/gaskets, magnet to recover metal parts in fluid.
- Clean shop rags and lint‑free cloths
- Purpose: wipe fluid and clean parts.
- How to use: keep the area clean; avoid leaving lint in valve body.
- Gasket scraper or plastic razor blade
- Purpose: remove old gasket material from pan and transmission mating surfaces.
- How to use: scrape gently at an angle to avoid gouging the surface; use solvent afterwards.
- Brake cleaner or parts cleaner (spray)
- Purpose: clean valve body and parts of old fluid and debris.
- How to use: spray and allow to drip into drain pan; use rags to wipe clean.
- Transmission fluid funnel with filter screen
- Purpose: refill ATF cleanly through the dipstick tube or fill plug.
- How to use: pour fluid slowly; the screen catches contaminants.
- New ATF fluid (Toyota‑approved type for your specific vehicle)
- Purpose: refill the transmission after work.
- How to use: use the type specified by the vehicle’s service manual or dipstick cap label.
- New transmission filter and pan gasket (or RTV sealant if pan has no gasket)
- Purpose: replace contaminated filter and seal pan to prevent leaks.
- How to use: swap old filter for new, ensure mating surfaces are clean and gasket/sealant properly applied.
- Replacement pressure regulator valve or valve body repair kit (if required)
- Purpose: replace a worn/stuck pressure valve or valve body parts.
- How to use: remove and install new valve according to service manual orientation; use new springs/balls as kit includes.
- Service manual (Toyota factory manual or reliable repair manual)
- Purpose: exact bolt torques, bolt lengths and tightening sequence, fluid capacity, and specific procedures.
- How to use: follow the manual’s illustrations and torque specs — indispensable for correct reassembly.
- Optional: transmission jack or another person to help
- Purpose: support or lower the valve body/pan safely if heavy or awkward.
- How to use: support pan or valve body during removal to prevent sudden drop or damage.
Step-by-step procedure (generalized — consult service manual for model‑specific details)
- Prepare vehicle: chock wheels, lift with floor jack, place on jack stands, disconnect battery if needed.
- Position drain pan under transmission pan and remove the lowest pan bolt or loosen bolts around the pan to let ATF begin draining slowly; allow most fluid to drain before fully removing pan.
- Remove all pan bolts and lower the pan carefully — it will still have fluid and may be heavier than expected. Use a second person if needed.
- Remove the old filter (it’s usually held with a few screws or just pushed in). Note its orientation. Expect more fluid to drain when removing the filter.
- Inspect the pan for metal shavings or clutch material; heavy contamination indicates internal wear and needs further diagnosis.
- Clean the pan, magnet plate, and mating surface with brake cleaner; scrape old gasket material carefully.
- With the pan and filter removed, you’ll see the valve body. The pressure regulator valve is generally inside the valve body assembly or in a bore in the valve body cover.
- Identify the pressure regulator valve assembly (use the service manual diagram). It often consists of a spring, valve spool, and a small ball or plunger.
- Remove valve body bolts gradually and evenly, and lower the valve body assembly just enough to access the regulator valve bore. Support the valve body; do not let it hang by wiring or solenoids.
- Carefully remove the regulator valve components (spring, spool, balls, or check balls) into a clean tray in the order removed. Use a magnet and pick to retrieve small parts.
- Inspect the valve spool and bore for scoring, pitting, sticking varnish, or wear. Slight dirt can cause valve sticking.
- Clean the valve bore and spool with parts cleaner and lint‑free cloths. If the spool moves freely after cleaning and no scoring or worn surfaces are present, you may reassemble with a new filter and gasket.
- If the valve spool or bore is scored, pitted, or damaged, replacement is recommended. Options:
- Replace the individual pressure regulator valve kit (OEM or quality aftermarket kit with spool, springs, balls, seals).
- Replace or rebuild the valve body if damage is extensive.
- Install replacement parts in the exact orientation and order they were removed. Use the service manual diagrams for orientation and any required lubricants (light film of clean ATF on parts before assembly).
- Reinstall valve body and torque bolts to factory specifications in the specified sequence. Reconnect electrical connectors and wiring harnesses you removed.
- Install new filter and new pan gasket (or apply correct RTV if applicable). Clean mating surfaces thoroughly.
- Reinstall pan and tighten pan bolts in a crisscross pattern to the torque specified in the manual.
- Refill transmission with the correct amount and type of ATF through the dipstick tube or fill plug using a funnel. Start with the amount equal to drained amount plus some allowance; final level must be checked warm per the manual.
- Start the engine, cycle gear selector slowly through all gears, return to Park, and with engine idling and transmission warm to normal operating temperature, check fluid level and add as needed to reach proper cold/warm level per manual procedure.
- Check for leaks and test drive to ensure proper pressure and shifting. Recheck fluid level and leak points after a short road test.
How to use key tools correctly (quick practical notes)
- Ratchet and sockets: make sure the socket fully seats on the bolt head; pull rather than push when possible to avoid slips. Use extensions to reach recessed bolts.
- Torque wrench: set value, snug bolts progressively in proper sequence, then set final torque — do not “guess” torque.
- Jack and jack stands: always raise vehicle high enough before placing stands; rock vehicle lightly after lowering onto stands to confirm stability.
- Drain pan and funnel: keep a dedicated container for used ATF; store and dispose of used ATF per local regulations.
- Pick and magnet: use picks to remove seals; magnet to recover balls/small metal parts — avoid scratching bores.
Parts replacement guidance (what needs replacing and why)
- Transmission filter and pan gasket — replace every time the pan is dropped:
- Why: filter traps debris; a clogged filter reduces flow and pressure. Gasket prevents leaks.
- What to buy: OEM filter and gasket kit for your Toyota model/year or a high‑quality aftermarket kit that specifies compatibility with A442F.
- Pressure regulator valve / valve body parts — replace if worn or stuck:
- Why: worn/spotted spools or corroded bores cause incorrect line pressure (harsh shifts, slipping, overheating). Cleaning may help temporarily, but damaged parts require replacement.
- What to buy: valve repair kit (includes spool, springs, balls, seals) for A442F or complete valve body rebuild kit. If damage is extensive, replace valve body assembly or buy a remanufactured unit.
- Pan bolts or crush washers (if applicable) — replace if damaged or if manufacturer recommends one‑time use bolts.
- Why: prevents leaks and ensures proper clamping force.
- ATF fluid — replace/refill with Toyota‑specified ATF:
- Why: old/degraded fluid loses hydraulic properties and causes valve sticking and wear.
- What to buy: the exact ATF type recommended in the service manual or on the transmission dipstick cap.
Symptoms indicating the regulator valve is bad (why replace)
- Harsh or delayed shifts, slipping, or inability to hold pressure.
- Transmission overheating accompanied by contamination in the pan.
- Erratic line pressure or diagnostic trouble codes referencing pressure control.
- Valve sticking on inspection (visible scoring or stuck movement).
Final notes and warnings
- Do not force parts into bores; note orientation and order of components as you remove them.
- If you are not confident removing the valve body or handling small precision parts, consider professional service. Valve bodies contain small check balls and springs that, if assembled incorrectly, cause transmission failure.
- Always use the correct ATF and torque values from the Toyota service manual for your vehicle’s year and engine combination.
No yapping — follow these steps, use the tools as described, replace the filter/gasket at minimum, and replace the regulator valve or valve body if inspection shows scoring, pitting, sticking, or other damage. rteeqp73