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
Quick overview (one-sentence): The “accelerator linkage” on a Toyota A442F automatic is the throttle-to-transmission cable linkage (TV/kickdown cable, brackets, clips and bushings) that tells the transmission how hard you’re asking the engine to work so the valve body sets line pressure and shift timing — repairing it fixes wrong shift points, harsh or delayed shifts, slipping or lack of kickdown.
Theory — why this matters (simple, mechanic-level explanation)
- The transmission does not “read” the gas pedal directly. It uses a mechanical cable (throttle valve or kickdown cable) and its lever on the transmission to translate throttle position into hydraulic input (line pressure and shift timing) in the valve body.
- Think of the TV cable like a puppet string: the throttle (puppet master) pulls the string and the TV lever (puppet) moves the valve inside the transmission. If the string is loose, frayed, or misrouted, the puppet won’t move correctly — the transmission will shift at wrong times or use incorrect pressure.
- There are two related functions: (1) steady mapping of throttle to line pressure/shift schedule (TV function) and (2) rapid downshift when you floor the throttle (kickdown). Both rely on correct geometry and free movement of the cable and lever.
Primary components (every part you’ll see and how each works)
- Accelerator pedal & return spring: initiates throttle motion. Not usually changed for trans linkage work, but pedal travel sets cable input.
- Throttle cable (accelerator cable): connects pedal/throttle body to engine throttle. Often shares routing with cruise control cable. Can stretch or fray.
- Kickdown/TV cable assembly (sometimes one cable doing both functions or two separate): the metal inner cable (slides inside housing) transmits motion; outer housing anchors to fixed bracket points. Inner cable eyelet connects to throttle lever or to a linkage.
- Cable housing end fittings and rubber grommets: insulate and locate the housing ends at brackets/ firewall; worn grommets allow cable movement or chafing.
- Cable bracket(s) and mounting bolts: secure the cable housing to firewall/transmission throttle lever; a bent or loose bracket changes cable geometry.
- Adjuster (barrel or threaded adjuster with locknut): used to set free play and initial cable tension. Locknut secures the adjustment.
- Clevis, pin, snap ring / E-clip / retaining clip: the small connector pieces that secure the cable eye to the throttle or TV lever. If missing or worn, cable can pop off.
- TV / kickdown lever on the transmission (small lever on the exterior of the A442F): translates cable pull into internal valve adjustments. Has a pivot, detents or stops and sometimes a return spring.
- Return spring on TV lever: ensures the lever returns to rest at idle; weakened springs change behavior.
- Bushings / sleeves between cable eye and lever: reduce wear and keep geometry correct; if worn, allow slop.
- Throttle body lever / carburetor linkage (where cable attaches on the engine): the engine end that moves with pedal; cruise/throttle bracketry may be nearby.
Common failure modes — what can go wrong and how it shows up
- Cable stretch or fraying: increased free play, delayed upshifts, late kickdown, intermittent downshift.
- Broken inner cable or popped end fitting: no kickdown, loss of transmission responsiveness.
- Worn bushings/grommets: binding or extra slop (inconsistent shift feel).
- Bent/misaligned bracket or seized adjuster: wrong geometry, causing too high or low line pressure and harsh/soft shifts.
- Broken TV lever spring or seized pivot: lever doesn’t return or doesn’t travel fully — can cause slipping or failure to downshift.
- Incorrect adjustment: too tight = harsh shifts, excessive line pressure (wear, overheating); too loose = soft shifts, delayed upshifts, possible slipping.
- Corrosion/rust or chafing: cable can bind in the housing and stick.
Tools and materials you’ll need
- Basic hand tools: sockets, ratchet, open-end wrenches (metric), screwdrivers, pliers.
- Needle-nose pliers, snap-ring pliers (if retaining clips used).
- Replacement parts: new TV/kickdown cable assembly (OEM or quality aftermarket), grommets/bushings, clips, bracket if damaged, lubricants (white lithium or cable lube), small wire or zip ties to hold things during routing.
- Penetrating oil (if bolts are rusty), rags, safety glasses, work gloves.
- Car jack and stands (if needed to access transmission area). Wheel chocks.
- Torque wrench and owner/service manual (for torque specs and adjustment figures) — consult manual for exact numbers.
Step-by-step repair procedure (beginner-friendly, clear order)
Safety first:
- Park on level ground, engine off, parking brake on, wheels chocked. Disconnect battery if you will work near electrical connectors or risk shorting. Wear gloves and safety glasses.
Access and inspection:
1. Locate the cable route: from the throttle body/pedal through firewall into engine bay down to the transmission TV/kickdown lever on the A442F.
2. Inspect visually: look for frayed cable, missing clips, cracked grommets, rusted bracket bolts or bent brackets. Move the throttle by hand (engine off) and watch the TV lever move — should be smooth and immediate.
Removal:
3. Mark positions: before removing, mark the position of the TV lever and cable/adjuster with a scribe/marker so you have a reference for reassembly.
4. Loosen the locknut on the adjuster at the throttle side (or transmission side, depending on design).
5. Disconnect the cable end from the throttle lever: remove clevis pin / E-clip / retaining clip. Keep hardware if reusing and in good shape.
6. Remove any cable retaining clips or bolts securing the housing to brackets (firewall bracket, engine bracket).
7. Pull cable out of grommets; remove through firewall if needed.
Inspection and replace:
8. Compare new cable to old: length, end fittings, grommet dimensions must match. Replace grommets/bushings and any clips.
9. Clean mounting points and lightly lubricate moving pivots and pivot pin on TV lever. Do not pack transmission lever pivot with heavy oil; use light grease or a little penetrant on corroded pivots and then grease.
Install new cable:
10. Route new cable exactly as old one was routed — no tight bends, no pinch points, keep adequate clearance to heat and moving parts.
11. Install housing ends into their grommets and secure brackets loosely (so you can still rotate adjuster).
12. Attach cable eye to TV lever with clevis pin and retaining clip. Make sure pivot is seated and spring installed correctly.
Initial adjustment (static)
13. With throttle at idle (engine off) and pedal at rest, set adjuster so there is a small amount of free play in the cable at the throttle and at the TV lever. “Small amount” means the cable just goes slack a few millimeters — you should not be preloading the TV lever at idle.
14. Tighten adjuster locknut to hold setting. Secure bracket bolts snugly (consult manual for torque; if no manual, tighten securely but avoid over-torquing plastic parts).
Functional checks (static, before starting engine)
15. Move pedal/ throttle by hand through full range; observe TV lever: it must move smoothly from rest to full travel without binding and must return fully when released. If sticking, re-check routing and bushings.
16. Verify clip/pin is secure and return springs are hooked correctly.
Adjustment fine-tune (engine running and road test)
17. Start engine, allow to reach normal idle. Re-check idle and cable slack because settling may change slack slightly.
18. With assistant gently blip the throttle while you observe TV lever movement: it should move proportionally and return immediately.
19. Road test in a safe area: perform gentle acceleration and note shift points under light throttle; then perform firm acceleration to verify kickdown downshift works. If shifts occur too early or too late, adjust accordingly:
- If upshifts occur too early/soft (engine revs low): reduce slack (i.e., increase cable tension slightly — pull cable a bit).
- If upshifts are harsh/late or transmission seems to slip: add a touch more slack.
20. Make small adjustments (1/8–1/4 turn) and retest until shift behavior is correct and consistent across partial and wide-throttle inputs.
Finalize
21. Tighten all bracket bolts and locknuts, secure clips and any heat shields you removed. Reinstall any removed components, reconnect battery if you disconnected it.
22. Dispose of old cable properly; check for any fluid leaks around the TV lever area (shouldn’t be any, but check seals).
Troubleshooting tips and things beginners commonly miss
- Always re-route exactly like original. A new route over a sharp edge or hot surface will destroy the cable quickly.
- If cable binding occurs at extreme travel, check that the adjuster isn’t bottoming out on its threaded housing — you must have enough adjuster thread to move but not so much that it interferes.
- If you get no downshift on hard throttle after correct adjustment, inspect the TV lever return spring and the lever pivot for wear or seized parts. Also confirm throttle body linkage is not binding.
- Don’t over-tighten the cable so the TV lever has preload at idle — that raises line pressure and hastens transmission wear and overheating.
- If a new cable shows the same symptoms as the old one, investigate other causes: worn valve body, internal transmission issues, or vacuum/electronic controls (depending on vehicle year).
Safety notes and caution
- Never work under a vehicle supported only by a jack. Use stands.
- Be careful around a running engine — moving parts and hot components.
- If you’re not comfortable diagnosing shift timing vs. mechanical cable problems, don’t ignore signs of slipping or overheating — internal transmission damage happens quickly if line pressure is wrong.
Quick checklist for a successful repair
- Replace frayed/stretched cable, worn grommets, and missing clips.
- Ensure smooth routing, no kinks, and correct grommet seating.
- Set small idle slack, then fine-tune with dynamic tests.
- Confirm TV lever moves smoothly and returns fully.
- Road-test both light and full-throttle shifts; re-adjust if necessary.
If you want a service-manual level spec, consult Toyota’s A442F service manual for the exact cable free-play numbers, torque specs, and the manufacturer’s adjustment procedure; use those final numbers to lock the job in. rteeqp73
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