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Toyota A442F Automatic Transmission factory workshop and repair manual

Short version: this is a major job — transmission removal and a bench disassembly to press out and replace the input‑shaft bearing. Read the Toyota A442F factory service manual for exact torque specs, clearances, and sequences. Below I give the theory, a detailed list of components, the full step‑by‑step procedure with important tips, and what commonly goes wrong.

Why this repair is needed (theory)
- Function: the input shaft is the first spinning part the torque converter drives into the transmission. The input‑shaft bearing supports and centers that shaft in the front case/pump so the shaft spins true and the oil pump gears stay meshed and sealed.
- Bearing failure effects: worn or seized bearing lets the input shaft wobble or sit off axis. That causes pump gear clearance problems (low pressure), abnormal wear of gears and clutches, whining/grinding noise, metal debris in the fluid, overheating, slippage and eventual catastrophic failure.
- Analogy: think of the input shaft as an axle and the bearing as the bearing on a bicycle wheel. If the bearing goes bad the wheel wobbles and stresses the hub, spokes and fork. In a transmission a wobbling input shaft stresses the pump, planetary gears and clutches and quickly creates more damage.
- Symptoms that point to the input bearing: growling/whining from the front of the transmission that changes with engine RPM, low line pressure, metal in the pan/magnet, excessive input shaft endplay, oil leaks from the front pump area.

Main components you will encounter (brief descriptions)
- Torque converter: fluid coupling mounted on the engine flexplate that drives the input shaft via the pump and converter hub.
- Front pump (oil pump / pump housing): bolts to the front of the case; contains the pump gears and often the bearing/bearing retainer area that supports the input shaft.
- Input shaft: splined shaft that the torque converter drives; it carries clutch hubs and sun gear input connections.
- Input‑shaft bearing(s): roller/ball or needle bearings that support the shaft in the front pump or case.
- Pump drive gear / driven gear: meshed gears that feed oil pressure; vital clearances depend on proper shaft location.
- Planetary gearsets & clutches: rearward assemblies that provide the gear ratios.
- Valve body and oil passages: control hydraulic circuits and must be kept contaminant‑free.
- Seals, O‑rings, thrust washers, snap rings: small parts that retain position and control fluid leaks and endplay.
- Case / bellhousing: houses everything and bolts to the engine.

Required tools & supplies (minimum)
- Factory service manual for A442F (essential).
- Transmission jack or strong floor jack + heavy support (transmission weight).
- Engine support or engine hoist/adapter if needed to separate from engine.
- Full hand tool set (sockets, extensions, wrenches).
- Torque wrench.
- Snap‑ring pliers, gear pullers.
- Press or hydraulic bearing driver set and appropriate receivers (bench press recommended).
- Bearing drivers / sleeves sized to press on appropriate race only (do not press on the inner race unless specified).
- Seal drivers.
- Dial indicator (for endplay checks) and small feeler gauges.
- Cleaning solvent, lint‑free rags.
- New input shaft bearing(s), front pump seal(s), paper gaskets and/o r RTV as called for, transmission filter and gasket, ATF (correct type), and any other worn components you find.
- Replacement bolts where required, and safety gear (gloves, eye protection).

High‑level safety notes (read before starting)
- Disconnect battery. Support vehicle on level surface with quality jack stands. Do not rely on hydraulic jack alone.
- Transmission removal is heavy and dangerous — use a proper transmission jack or helper.
- Keep work area clean and organized to avoid contaminating parts.
- Always follow factory torques and assembly order from the manual.
- If you don’t have a press or feel unsure about pressing bearings correctly, use a shop or transmission specialist. Incorrect pressing damages bearings and shafts.

Step‑by‑step procedure (detailed)
I. Preparation and removal from vehicle
1. Park, chock wheels, disconnect the negative battery cable.
2. Raise and secure vehicle on stands so you can access driveline and transmission comfortably.
3. Drain ATF into a clean drain pan (remove pan or drain plug if present). Save fluid for inspection (look for metal flakes).
4. Remove driveshaft(s) or propeller shaft and tail housing/transfer case if 4x4 — separate transfer case from transmission if needed.
5. Disconnect transmission cooler lines (cap them to avoid contamination), speedometer cable/sensor, starters, electrical connectors, ground straps, vacuum/shift linkages and the shifter cable/linkage.
6. Support the engine as needed (subframe or engine support) if transmission removal will alter engine support.
7. Support transmission with transmission jack and unbolt the crossmember and transmission mounts.
8. Rotate converter to access and remove torque converter-to-flexplate bolts (if accessible) or remove converter after separating the transmission from the engine. Mark converter position relative to flexplate for reassembly.
9. Unbolt bellhousing-to-engine bolts. Slowly slide transmission rearward off the engine, ensure converter disengages and no wiring/oil lines are snagged. Lower transmission safely to bench.

II. Bench disassembly to access the input shaft bearing
10. Clean exterior of transmission before opening — prevents dirt entering case.
11. Remove torque converter from the input shaft and set aside; examine for wear or bearing noise in the hub.
12. Remove transmission pan, filter and valve body (follow manual; note bolt order and check for checkballs).
13. Remove planetary/clutch assemblies as required to free the front pump/pump housing. This typically involves removing snap rings, clutch hubs, steels/plates and planetary carriers. Keep parts in order, label or photograph each stack.
14. Remove front pump bolts and separate the pump housing from the case. The input shaft bearing is usually in the front pump/pump housing or retained by a bearing retainer at the front of the pump. Inspect the pump drive gear and mating gears — bearing play here is critical for pump pressure.
15. With pump removed, inspect the input shaft forward end for the bearing and retainers. Remove any retaining circlips or bolts that hold the bearing retainer.
16. Use proper puller or press to remove the bearing from the shaft or from the pump housing. Note orientation: inner/outer race positions matter. Do not pry on races or use impact methods that deform components.

III. Inspection & preparation for new bearing
17. Thoroughly clean the shaft, housing faces, oil passages and pump gear bores. Remove all metal flakes and contaminant.
18. Inspect the input shaft for shaft scoring, pitting or tapered wear. If the journal is damaged, replace or recondition the shaft — do not install a new bearing on a damaged journal.
19. Inspect the pump gear bores, bearing seats, thrust washers, snap rings and seals. Replace any worn bushings, thrust washers or seals.
20. Check bearing seat tolerances per the manual. If seats are out of tolerance, the pump or case may require repair or replacement.

IV. Installing the new bearing
21. Clean new bearing and lightly lubricate with ATF where required (factory instruction).
22. Use a press and correct driver to press bearing on/off. Important: press only on the race that the press must act upon per bearing design — pressing on the wrong race destroys the bearing. If the bearing must be pressed into a housing, support the housing to avoid distortion.
23. Install any bearing retainer plate, circlips or stop bolts and torque to specification (see manual).
24. Replace front pump seal(s) with new ones, using a driver sized to seat seal squarely.
25. Reassemble pump to case, making sure internal clearances are correct and that pump gears are aligned per manual. Torque pump bolts to spec.

V. Reassembly
26. Reinstall planetary assemblies, clutches, steels and friction packs in the exact order. Replace any worn clutches/frictions if they show glazing or wear.
27. Reinstall valve body and filter with new gasket. Replace the pan gasket or use correct RTV where specified.
28. Install torque converter carefully onto the input shaft, making sure it fully engages the pump drive and that it slides in to the proper depth. Rotate converter while pushing in to seat splines — not forcing.
29. Lift transmission and mate to engine, align and install bellhousing bolts and torque to spec. Install torque converter bolts to flexplate in correct order and torque.
30. Reconnect all lines, mounts, electrical connectors, driveshafts and the transfer case (if used).
31. Refill with the correct type and amount of ATF.
32. With the engine running and the transmission warm, check fluid level per the manual procedure; fill only to the correct hot level.

Checks and measurements you must perform
- Input shaft endplay: measure with dial indicator and compare to factory spec. Excessive endplay indicates improper assembly or worn thrust washers.
- Pump gear clearance/relief: as manual instructs — low pressure often originates from poor pump clearances.
- No new leaks from front pump seal or pan gasket.
- Line pressure check at key points (park/neutral, 1st/2nd gear) with pressure gauge to confirm pump/pressure integrity.

Common mistakes and what can go wrong (and how to avoid it)
- Pressing on the wrong race and destroying a new bearing — always use proper driver that contacts the correct race.
- Not replacing seals/filters — leads to early failure and contamination.
- Contaminating valve body/precision surfaces with dirt — keep everything immaculately clean.
- Improperly seating the torque converter on the input shaft before bolting to flexplate — if not seated fully you can crack the pump or damage the converter engagement, causing immediate failure. Always rotate and push until it bottoms out; you should feel multiple spline engagements.
- Reusing worn thrust washers or bushings — causes endplay and premature bearing failure; always inspect and replace worn wear items.
- Not checking pump and shaft journals for damage — replacing only the bearing when the shaft/journal is scored will fail quickly.
- Incorrect bolt torques, missing snap rings — causes shifting problems, internal collapse or leaks.
- Not checking for metal shavings throughout: if you find significant metal, clean entire system thoroughly and consider full rebuild rather than partial replacement.

When to stop and seek professional help
- If shaft journals are damaged or you are unsure of acceptable tolerances.
- If you lack a press or proper bearing drivers.
- If you find extensive metal/gear damage — a full rebuild or replacement is often safer and cheaper in the long run.

Final test and break‑in
- After reassembly and refilling, test drive gently. Avoid heavy loads for the first 100–200 miles. Monitor temperature, fluid level and listen for noises. Recheck fluid level after run‑in.

Estimated time and difficulty
- Difficulty: advanced/experienced DIY (bench transmission work). Not a beginner project unless you’re comfortable with heavy components and precision assembly.
- Time: typically a full day or more if you have the proper tools; longer if problems are found.

Parts checklist (minimum replacements recommended)
- Input shaft bearing(s) (OEM quality).
- Front pump seals and O‑rings.
- Transmission filter and pan gasket.
- Any snap rings/thrust washers/bushings that are worn.
- ATF (specified type).
- Gaskets/RTV, bolts if needed.

Closing/brief checklist before final assembly
- Cleanliness: no grit, lint, metal particles.
- Bearing installed and retained correctly.
- Seals seated squarely.
- All snap rings present and in the right orientation.
- Endplay within spec.
- Torque values per factory manual used on all critical fasteners.

That’s the complete procedure overview and detailed guidance for replacing the input shaft bearing on an A442F. Follow the A442F factory service manual for torque numbers, clearances, and disassembly diagrams. If at any point the journal or pump faces are scored or out of tolerance, stop and have the parts inspected by a machine/transmission shop.
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