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 & supplies
- OEM-specified ATF (check vehicle tag/service manual; many Toyota autos use Type T-IV or WS depending on year) — buy full capacity + 2 qts for exchange/overfill.
- Transmission filter kit (filter + pan gasket + pan magnet if separate) and new cooler line crush washers (if applicable).
- Fluid catch pan (large).
- Pump-style fluid-exchange machine or hand pump (12–18 l/min) and clear hoses OR a hand siphon and jugs for multiple drain/refill cycles.
- Radiator/cooler line disconnect tool (Toyota/quick-disconnect type) or 1/4" screwdriver and pliers if factory clip type.
- Floor jack + quality jack stands or a lift.
- Basic hand tools: socket set, ratchet, extensions, screwdrivers, pliers.
- Torque wrench (for pan bolts).
- Gasket scraper / solvent and shop rags.
- Rubber gloves, safety glasses.
- Funnel, clean plastic jug for new fluid, marker to label old fluid.
- ABSORBENT pads/kitty litter and container for recycling fluid.
Safety precautions
- Work on level ground. Engage parking brake, chock wheels.
- Use jack stands — never rely on the jack.
- Transmission fluid is hot: warm engine only, then stop and allow a short cool-down to avoid burns. Wear gloves/eye protection.
- Avoid ignition sources; ATF is flammable. Dispose/ recycle fluid per local regs.
- If using an exchange machine, follow machine instructions and ensure all hose connections are secure.
Which flush method (two options)
- Partial “drain & refill” (very common, easy): remove pan, replace filter/gasket, drain pan fluid, reinstall and refill. Removes ~30–40% of fluid per pan drop. Repeat fill/drain cycles 2–3 times to remove more old fluid.
- Full “exchange” using a pump/fluid-exchange machine: best for full capacity change including torque converter/cooler. Requires connecting to cooler lines or to cooler inlet/outlet at radiator and running engine while the pump replaces fluid.
Step-by-step — Drain & refill with filter change (recommended minimum)
1. Warm the vehicle to normal operating temperature (drive 10–15 min). This lowers fluid viscosity and helps drain contaminants.
2. Park on level ground, set parking brake, chock wheels, raise front with jack and secure on stands.
3. Place catch pan under transmission pan. Remove most pan bolts, loosen and let pan drain (careful — hot fluid). Remove pan fully.
4. Inspect pan magnet(s) and clean metal debris with a rag; note amount of material (a little is normal; chunks/large shavings are a problem).
5. Remove old filter: either pull straight down or remove retaining bolts (depends on model). Replace with new filter from kit. Lubricate new gasket lightly with clean ATF.
6. Clean pan mating surface on transmission and pan. Scrape old gasket residue. Ensure surface is dry and clean.
7. Install new pan gasket and re-fit pan. Torque bolts to factory spec in a criss-cross pattern (if you don’t have spec, snug all evenly, then torque to a moderate value — check service manual; over-torquing deforms the pan).
8. Refill through dipstick tube with the correct ATF. Add the amount removed from pan plus the amount stated in manual for a pan/filter change (typically several quarts). If unsure, start with 3–4 qts less than total capacity; you will top up after level check.
9. Start engine, let idle, shift through all gears slowly, return to Park. With engine idling, check fluid level on dipstick per manufacturer procedure (level at specified temperature; many Toyota checks done hot with engine idling). Add fluid slowly to reach proper level.
10. Lower vehicle, test drive to warm up, re-check level and for leaks.
Step-by-step — Full exchange using a pump/exchange machine (recommended for full replacement)
1. Warm vehicle, safety setup on stands.
2. Locate transmission cooler lines (usually at radiator or the transmission cooler; one supply, one return). Identify the return line from transmission cooler to radiator. It’s usually the lower line.
3. Using the correct disconnect tool, disconnect the cooler line(s) at the radiator or quick-disconnect fitting. Be prepared for fluid spill. Replace crush washers if lines use banjo fittings.
4. Connect exchange machine hoses: machine inlet hose to the transmission cooler return (this pulls old fluid out) and machine outlet hose to the cooler feed (or to the transmission cooler input) depending on machine instructions — follow machine piping so that new fluid flows into the transmission where old fluid is being removed. Secure clamps.
5. Fill the exchange machine reservoir with new ATF. Start the machine to begin pumping new fluid in while old fluid is drawn out. With engine idling and machine running, have an assistant cycle the shifter through all gears slowly to help purge the torque converter. Monitor outgoing fluid until it runs clear and the color matches new fluid. Exchange the number of liters/quarts equal to transmission capacity (or until clear) — typically you’ll need more than the capacity because converter exchange requires multiple passes.
6. Once exchange is complete, stop machine, remove hoses and immediately reconnect cooler lines with new crush washers/clips. Tighten to spec.
7. Top up ATF to specified level via dipstick, start engine, cycle gears, check level hot, adjust to proper mark. Check for leaks.
How the exchange tool is used (practical notes)
- Machine pumps new fluid in at a controlled rate while drawing old fluid out; it should be connected so you’re not pumping against closed passages. Most machines have clear hoses — watch outgoing fluid for clarity/foam.
- Always run machine with engine idling (not high RPM) so the pump and torque converter circulate normally.
- Keep an eye on fluid temperature and level at the dipstick: do not overfill during exchange.
- Follow the machine manufacturer’s priming and bleed steps to avoid air ingestion.
Replacement parts typically required
- Transmission filter and pan gasket kit (recommended every time you drop the pan).
- Cooler line crush washers or O-rings (replace if removed).
- New ATF — quantity depends on method and model. Buy OEM-approved ATF.
- Optional: new pan bolts if threads/pans are damaged; pan gasket adhesive if OEM recommends.
Common pitfalls & how to avoid them
- Overfilling or underfilling: always check level with engine warm and follow manufacturer procedure. Overfill causes overheating/foaming.
- Not replacing filter or gasket: leaves contaminants and leaks. Always replace filter when you drop pan.
- Not warming fluid: cold fluid won’t drain fully; warm engine first.
- Not cycling gears during refill: air pockets remain; cycle through gears to purge air and circulate fluid.
- Improper torque on pan bolts: overtighten = warped pan/leak; under-tension = leaks. Use a torque wrench and pattern.
- Ignoring magnets: heavy metal shavings indicate internal wear—inspect and consult shop if excessive.
- Using wrong fluid: wrong ATF can cause harsh shifts and damage. Confirm spec.
- Not cleaning mating surfaces: causes leaks.
- Disconnecting wrong cooler line / damaging radiator: use correct disconnect tool and be gentle with plastic fittings.
Final checks
- Run engine to operating temp, cycle through gears, re-check fluid level and top to spec.
- Inspect for leaks around pan and cooler lines.
- Re-check level after a short road test and again after 100–200 miles.
Do not attempt complex exchange if you’re not confident with cooler-line disconnects or with running equipment — have a shop do a pressurized torque-converter exchange. rteeqp73
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Short summary
- The transmission breather hose is a small rubber tube that vents pressure from the transmission case to atmosphere (usually routed up into the engine bay). Replacing or repairing it is simple but important: a blocked or damaged breather causes pressure build-up that forces fluid past seals (leaks) or allows dirty/wet air into the case. Below I describe every component, how the vent system works (theory), step‑by‑step how to inspect/replace the hose on a Toyota A442F-style transmission, and common failure modes and fixes. No fluff.
Parts and components — what everything is and what it does
- Transmission case: the large aluminum/steel housing that contains gears, clutch packs, pump and fluid. It has a small boss/port for the breather.
- Breather port (vent boss): a small raised hole in the case where the breather cap or grommet fits. It is the passage between the interior and the outside.
- Rubber grommet / molded breather cap: a rubber piece that seals the port and gives a tight connection to the hose. Some cars use a simple rubber plug with a nipple; others use a plastic breather cap with a built‑in filter or one‑way valve.
- Breather hose: typically a short length (300–600 mm) of flexible fuel/vacuum hose (approx. 4–8 mm ID, commonly 1/4"–5/16" or 6 mm) that connects the breather cap to the routing point. It keeps the vented air away from road spray and hot components.
- One‑way check valve / filter (optional): some systems include a small check valve or mesh filter at the hose end to keep water/dirt out while letting air escape.
- Clips, clamps, zip ties, and routing brackets: secure the hose along the firewall or to the airbox to keep it up high and away from road spray, heat and moving parts.
- End termination: usually just open in the engine bay, routed up and clipped high. Some vehicles route into the engine air intake or to a filter.
Theory — why the breather exists and how the system works
- The transmission contains moving parts that agitate fluid and generate air bubbles and heat. When fluid heats or air is churned, internal pressure and trapped air increase. The breather gives a low‑pressure escape path so the case pressure stays near atmospheric.
- Analogy: the transmission is like a sealed water balloon with gear action inside. Without a tiny valve, internal pressure would push the water out through weak spots (seals). The breather is that valve — it lets excess air out so seals aren’t forced outward.
- The vent also allows the case to draw in outside air when it cools, so air flow occurs both ways. That’s why the breather should be located high and dry and often includes a filter/check valve to prevent water and dirt entering.
- If the breather is blocked, pressure spikes force fluid past seals and gaskets, causing leaks. If the hose is damaged or routed low, water/dirt can enter and contaminate fluid or cause corrosion/seal damage.
Common failure modes
- Hose cracked, perished, or split — allows road grime and water to enter or simply detaches.
- Hose routed down into splash area — water can be sucked into the case.
- Breather cap/grommet missing or hardened — creates a poor seal or allows contaminants in.
- Hose clogged with sludge or melted plastic — blocks venting and causes pressure build-up.
- Hose disconnected or chafed and rubbing on components — eventual failure and leaks.
- One‑way valve stuck or missing — allows ingress of contaminants or prevents venting.
Tools and materials you’ll need
- Replacement breather hose (6 mm / 1/4" ID vacuum/fuel hose — match original size; buy slightly fuel-resistant rubber hose).
- Replacement rubber grommet or breather cap if original is damaged.
- Small hose clamp(s) or spring clamps (usually optional if hose fits snug).
- Zip ties or OEM clips to secure routing.
- Pliers, flat screwdriver (for pry), hose cutter or utility knife.
- Rags, brake cleaner or solvent for cleaning area.
- Protective gloves and eye protection.
- Jack and jack stands if you need undercar access (safety first).
Step‑by‑step procedure (beginner friendly)
Preparation
1. Park on level ground, parking brake on, engine off and cool. If you must lift the vehicle, use a jack and support with stands—never rely on the jack alone.
2. Locate the transmission breather: on an A442F the vent is usually on the transmission case upper side/top or rear passenger side near the bellhousing/transfer area. Consult a vehicle-specific diagram if uncertain. You’ll see a short rubber nipple or grommet with a hose attached.
Removal of old hose and parts
3. Visually trace the hose from the port up into the engine bay. Note how it’s clipped or tied.
4. Remove any clips/zip ties holding the hose so you can pull it down. Use pliers or a screwdriver as needed.
5. Pull the hose off the breather port. If it’s stuck, twist gently while pulling. Don’t yank hard enough to damage the grommet.
6. Remove the breather grommet or cap if it’s damaged. Inspect the port for debris. If the hose is clogged, blow through it (if off the vehicle) to confirm airflow direction and cleanliness. If clogged with sludge, replace.
7. Clean the breather port and surrounding area with a rag and solvent so no dirt falls into the port during installation.
Install replacement components
8. Cut replacement hose to the same length as original or slightly longer so the end can be mounted up high. Make sure the hose has a smooth cut end.
9. If the original used a grommet or cap, install the new grommet on the port first. Ensure it seats fully — there should be a snug push‑fit. The grommet provides a sealed nipple.
10. Push the hose onto the nipple securely. If the fit is loose, use a small clamp or spring clamp on the nipple to secure it. If OEM used no clamp and the hose is a tight push fit, clamps are optional but won’t hurt.
11. Route the hose upward — always place the free end higher than the breather port, and away from exhaust, moving parts, and areas where it can collect road spray. Secure the hose to the firewall or airbox with zip ties or reuse original clips. Good routing means the hose end sits near the top of the engine bay or clipped to the fenderwell — not pointing down.
Optional: end termination
12. If you have a small plastic check valve or a breather filter, fit it at the open end. If not, leave the end open but pointed upward and tucked so it won’t collect water. Some people tuck the end into the airbox area above the air intake filter — that’s acceptable if the intake is sealed and the end won’t be exposed to heavy water spray.
Testing and final checks
13. Start the engine and listen/feel for abnormal sounds. With the engine idling, gently rev and watch for any signs of fluid seeping around the breather port. A correctly functioning breather should not leak under normal operation.
14. After a short drive, recheck hose routing and secure points for movement. Inspect transmission area for new leaks.
15. Monitor the transmission fluid level and check for contamination (milky or foamy fluid indicates water/air contamination). If you suspect water ingress or prolonged blockage, plan a fluid and filter change.
Troubleshooting quick guide
- If you see fouled, milky fluid: likely water contamination. Drain and replace transmission fluid and filter; correct vent routing; check seals.
- If leaks persist after replacing hose: leak source may be a failed seal (input/output shaft seal, pan gasket). The breather fix stops pressure but damaged seals may require replacement.
- If hose keeps clogging or it’s a high-dust/wet environment: add a small breather filter or one‑way valve and route the end into a protected area (airbox) or replace periodically.
- If transmission shows foamy fluid or erratic shifting: trapped air from a blocked breather can aerate fluid—replace hose and consider a fluid change.
Maintenance tips and best practices
- Use hose that resists oil and heat (vacuum/fuel hose rated for engine bay).
- Route the breather to a high, dry spot; avoid exhaust manifolds and wheel wells where water splashes.
- Inspect the breather hose during regular oil/service intervals; replace any hose older than ~5–10 years or showing cracks.
- If you need to drive through deep water, temporarily secure the breather higher if possible to avoid water ingestion.
- When in doubt, replace the grommet and a short length of hose — it’s inexpensive insurance.
Why this small part matters
- The breather is a tiny component but critical: without it, the transmission will build pressure and force fluid past seals. Replacing a cracked breather hose costs little; repairing a failed seal and cleaning contaminated fluid is much more expensive and time-consuming.
Done — concise checklist to replace a breather hose on an A442F
- Gather a matching 6 mm (1/4") hose, grommet/cap, clamps/zip ties and tools.
- Remove old hose, clean port, inspect grommet.
- Fit new grommet (if needed), push hose onto nipple, secure.
- Route hose high, clip/tie away from heat/wet areas.
- Start engine, check for leaks, drive and recheck.
That’s it — follow the steps above and you’ll have a properly functioning breather that protects seals and transmission fluid. rteeqp73
Toyota Land Cruiser - Chassis and Body factory workshop and repair manual Covers FJ40,FJ43, FJ45, FJ60, BJ40, BJ 42, BJ43, BJ45, BJ46, BJ60 series and HJ47 and HJ60 series Download on PDF