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
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. rteeqp73
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Tools & parts (minimum)
- Basic hand tools: 1/4" & 3/8" ratchets, metric sockets (8–17 mm), extensions, swivel.
- Torque wrench (in-lb / ft-lb range used on transmission pan/valves).
- Flat/Phillips screwdrivers, small picks.
- Transmission floor jack or transmission jack and engine support (if dropping trans).
- Safety jack stands, wheel chocks.
- Drain pan, funnel, clean rags, nitrile gloves, eye protection.
- Multimeter (DC volts/ohms).
- OEM-capable scan tool that can command/monitor transmission solenoids (bidirectional control).
- Small hand pump for refilling ATF (optional but handy).
- Brake cleaner or parts cleaner and lint‑free towels.
- New items: replacement “cold start injector” solenoid (OEM part number for your vehicle), new transmission filter, pan gasket or RTV as required, O‑rings/seals for the solenoid, fresh ATF (Toyota spec—see factory manual: T-IV/WS as applicable), new pan bolts if specified by manual.
- Optional: small magnet tray, light source, threading sealant (if required by manual).
Safety precautions (don’t skip)
- Work on a level surface. Chock wheels. Place car on jack stands; never trust only a jack.
- Allow vehicle and transmission to cool before opening. Hot ATF and metal will burn.
- Disconnect battery negative cable before working on electrical connectors.
- Wear safety glasses and gloves. Keep solvents/ATF away from open flames.
- Keep magnets/trays for small parts — valve body components are easy to lose.
Overview / what you’re doing
- The “cold start injector” in Toyota A442F transmissions is a solenoid-type valve mounted in/near the valve body that controls hydraulics for cold shift strategy. Procedure: diagnose electrical/commandability, drop pan & filter to access valve body area, remove valve-body cover/bolts as required, replace solenoid and O‑rings, reassemble with new filter/gasket, refill ATF, clear codes and cycle/verify operation.
Step‑by‑step
1) Preliminary diagnosis (do this first)
- Connect scan tool, read transmission codes. Record codes.
- With connector attached, back-probe the solenoid connector or measure at harness plug: battery voltage with ignition ON, verify connector ground continuity.
- Use scan tool to command the “cold start” solenoid ON/OFF while monitoring voltage/current. Note if it responds.
- Use multimeter to measure solenoid resistance (back-probe at the solenoid connector): consult factory spec. If resistance is open/short or outside spec, replacement is needed. If scan tool cannot command solenoid or no voltage at harness, suspect wiring/ECU.
2) Prep vehicle
- Park, chock wheels. Raise vehicle and support on jack stands. Remove any underbody shields to access pan.
- Place drain pan under transmission. Remove transmission pan bolts on one side slightly lower than other to slowly drain fluid; fully remove pan once fluid mostly drained.
- Remove pan and set aside. Catch as much fluid as possible.
3) Remove filter and access solenoid
- Remove transmission filter (usually attached with bolts). Note orientation and any small parts (screen, O‑rings).
- Clean area so you don’t drop contamination into the valve body.
- Locate the solenoid/“cold start injector” — usually secured to the valve body or a small bracket. There may be a small valve-body cover that needs removal to access some solenoids. Keep bolts organized by length.
4) Remove solenoid
- Disconnect electrical connector; use pick to lift locking tang if present.
- Remove retaining bolt(s) and carefully remove solenoid. Inspect O‑rings; likely need replacement — discard old O‑rings.
- Keep track of any springs, check balls, or spacers — if the solenoid assembly includes removable components, lay them out in order and photograph for reassembly.
5) Bench / verify (optional but recommended)
- Compare old vs new solenoid: check pin spacing, O‑ring size, connector type.
- Measure resistance of new solenoid and old one with multimeter and compare to service specs.
- With a fused jumper and bench setup you can briefly apply 12V to confirm plunger movement — only if you know specs and keep it quick to avoid overheating. Best practice: use scan tool to test once installed.
6) Install new solenoid
- Lubricate new O‑rings with clean ATF. Insert solenoid straight into bore; do not twist or pinch O‑rings.
- Replace any valve-body cover and torque bolts to factory sequence & torque. If you removed the valve body, support it while removing bolts and do not let it hang by electrical connectors — use a transmission jack or support strap.
- Replace filter with new one and replace pan gasket or apply RTV per manual.
7) Refill & initial checks
- Reinstall pan bolts to spec (tighten in a crisscross pattern to specified torque).
- Lower vehicle to ground.
- Reconnect battery.
- Refill ATF to approx. “near full” cold level or per manual using the correct fluid type. If you have a pump, push fluid into dipstick tube.
- Start engine, let idle. With scan tool, command solenoid and watch for changes (pressures/shift behaviour). Look for leaks around pan and solenoid.
8) Final fluid level and road test
- Warm transmission to operating temperature per factory procedure (usually shift through gears, then idle until ATF 40–80°C depending on model). Check dipstick level with engine idling in Park/Neutral per factory instructions for hot measurement. Add fluid to correct level.
- Clear codes and perform a road test through all gears. Monitor for proper cold shifts vs warm shifts. Re-scan for codes.
Common pitfalls & how to avoid them
- Dropping balls/springs when removing valve body: take pictures, work on clean, flat surface, and use magnetic tray.
- Reusing old O‑rings or filter: always replace O‑rings and filter when accessing the valve body.
- Cross-threading or under/over-torquing pan/valve body bolts: use torque wrench and factory specs.
- Contaminated ATF or dirt in valve bores: clean around area before opening; keep everything covered and use lint-free towels.
- Using wrong ATF: use the Toyota-specified fluid (T-IV or WS depending on year/engine). Wrong fluid causes shift problems.
- Not checking wiring/harness: if new solenoid does not fix function, check harness for voltage and ground with scan tool and multimeter.
- Incorrect fluid level when cold vs hot: follow factory procedure — incorrect level leads to shifting and overheating.
Replacement parts required (typical)
- Cold start injector solenoid (OEM recommended).
- O‑ring kit for solenoid (often included with new solenoid).
- Transmission filter.
- Pan gasket (or RTV per manual).
- ATF (spec amount — check service manual for capacity).
- Optional: pan bolts, pan magnet clean/replacement.
How the key tools are used
- Scan tool: read codes, monitor solenoid status, command solenoid ON/OFF, view live data (pressures/temps) during testing and after installation.
- Multimeter: measure continuity/resistance of solenoid coil and verify harness voltage/ground. Back-probe connector with ignition ON for supply voltage.
- Torque wrench: tighten pan/valve‑body bolts to spec in the correct sequence to avoid warpage and leaks.
- Transmission jack/support: if valve body removal requires lowering the trans or supporting it, use proper support to prevent injury or component damage.
- Hand pump: for accurate ATF refill without spillage.
Final checks
- No leaks at pan or solenoid.
- No transmission codes and normal shift quality both cold and warm.
- Correct ATF level at operating temperature per factory procedure.
Follow factory service manual torque specs and procedures exactly for bolt torque, bolt lengths, and fluid level procedure. If you don’t have the manual, obtain the appropriate Toyota service data before beginning. rteeqp73
Short, ordered explanation with theory and how the repair fixes the fault.
1) Brief theory — what the “connecting rods” do on an A442F
- Function: the selector/shift connecting rods and linkage translate the driver’s gear selection (shifter position) into a rotary/linear motion at the transmission’s selector shaft/lever which positions the manual valve in the valve body. The manual valve routes hydraulic pressure to clutch packs/bands to select gears.
- Components involved: shift lever/cable, external connecting rod(s) or selector rod, retaining pin/clip at rod-to-lever joints, selector shaft/lever on the transmission, detent mechanism and neutral safety switch. Wear or misalignment at any joint changes lever geometry or free play and therefore manual-valve position.
- Fault effect: worn/bent rods or worn bushings/pins cause incorrect manual-valve position (partial engagement, wrong gear, harsh/late shifts, inability to engage gears, or slip). The repair restores accurate mechanical positioning so hydraulic circuits engage the intended clutches/bands.
2) Symptoms that point to connecting-rod/linkage faults
- Gear selected (shifter) not matching actual drive gear.
- Transmission hesitates, slips into limp gear, or engages unpredictably.
- Excessive free play at the shifter.
- Unable to select Park/Reverse/Drive smoothly.
3) Safety and prep (do first)
1. Park on level ground, chock wheels, set parking brake.
2. Disconnect negative battery terminal for electronic protection.
3. Raise vehicle safely on jack stands if needed to access linkage, or remove interior trim/console to get at shifter as required.
4. Have service manual/specs for A442F nearby (clearances, torques, indexing procedure).
4) Ordered repair procedure (practical steps, in order)
1. Verify symptom and mark shifter position: put shifter in Neutral and note transmission behavior; mark reference points on rod/lever with scribe/paint before removal to preserve indexing.
2. Access linkage: remove console/boots or outer dust covers to expose rod ends and retaining clips; if internal, remove shift cable bracket/retainer.
3. Support selector lever area of transmission so it cannot move under its own weight when rod is removed.
4. Remove retaining clips/pins at both ends of the rod (shifter end and transmission selector lever end). Keep orientation of any washers, spacers, collars.
5. Disconnect rod from the shifter and transmission lever. Inspect parts as you separate them for wear patterns.
6. Inspect components:
- Check rod straightness (roll on flat surface) and measure length vs specification.
- Inspect ball/joint ends, bushings, rubber boots, retaining pins for wear, elongation, corrosion.
- Inspect selector lever splines/shaft for wear or play; inspect detent spring and notches.
7. Replace worn items: new rod if bent/elongated; replace bushings, pins, clips, and any boots/seals. Use OEM parts or equivalent.
8. Reinstall in the reverse order but with precise indexing:
- Reconnect rod to selector lever and shifter using original orientation marks or service manual indexing method.
- Install new retaining clips/pins and any spacers in proper order; torque fasteners to spec.
9. Adjust neutral/park position if required:
- With shifter in Park (or Neutral as directed by Toyota spec), adjust rod length/position so the selector lever is at its specified index/stop.
- Some A442F adjustments require aligning a detent index or using a specified number of notches; follow the manual or align marks you made earlier.
10. Reconnect any shift cable brackets and neutral safety/backup switches; adjust their position per spec.
11. Reconnect battery, lower vehicle (if raised), reinstall console/trim.
12. Test operation before final torque/settling:
- Start engine, with park/brake check that gear selected matches indicated position.
- Cycle through gears with engine off and on, then perform a low-speed road test to verify positive engagement and proper shift timing.
13. Re-check fasteners and linkages after first road test.
5) How each repair action fixes the fault (theory tied to steps)
- Replacing bent/elongated rods restores correct rod length and straight geometry so the manual valve sees the exact intended displacement for each shifter position. That corrects wrong-gear selection and prevents partial engagement.
- Replacing worn bushings/pins removes slop at joints. Slop = lost motion = incorrect manual-valve position under load → slips, delayed or harsh shifts. New bushings transmit full motion and retain proper preload.
- Proper indexing/adjustment ensures the neutral/park mechanical stops match the valve-body neutral/park hydraulic position. This guarantees the detent and manual valve are aligned so the correct hydraulic circuits open for the selected gear.
- Replacing worn selector-lever/shaft or restoring detent functionality prevents unintended movement and ensures positive selection of detent positions, eliminating intermittent gear jumps or limp modes.
- Reinstalling seals/boots prevents contamination and premature wear, preserving long-term alignment and hydraulic response.
6) Verification after repair
- Shifter position equals engaged gear across all positions.
- No excessive free play at shifter.
- Smooth, correctly timed shifts under load without slipping or grind.
- No transmission fault codes (if equipped); clear and re-scan if needed.
7) Notes and cautions
- Always use OEM or equivalent parts for rod ends, pins, and bushings; incorrect parts can introduce play.
- If valve-body/manual-valve damage is suspected (i.e., internal scoring or hydraulic faults), linkage repair alone may not fix symptoms—hydraulic diagnostics will be required.
- Follow torque and indexing specs from Toyota service manual for A442F precisely.
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