Toyota A442F - FOREWORD

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Table of Contents

Foreword2
Introduction4
How to Use this Manual5
Preparation5
Repair Procedures5
References6
Specifications6
Cautions, Notices, Hints7
SI Unit7
General Repair Instructions8
Abbreviations Used in this Manual10
Standard Bolt Torque Specifications11
How to Determine Bolt Strength11
Specified Torque for Standard Bolts12
Table of Contents14
Description15
General Specifications16
Operating Conditions17
Function of Components18
Hydraulic Control System21
A.T. Fluid Temperature Warning System22
A.T.P. (Automatic Transmission Parking) Indicator22
SST (Special Service Tools)23
Recommended Tool24
Equipment24
Lubricant25
SSM (Special Service Materials)25
Component Parts Removala T26
- Separate Basic Subassembly29
- Remove Breather Lug and Hose29
- Remove Oil Cooler Pipes29
- Remove Neutral Start Switch29
- Remove Transfer Assembly30
- Remove Transmission Housing30
- Remove Oil Cooler Unions30
- Remove Transmission Temperature Sensor30
- Remove Oil Pan31
- Examine Particles in Pan31
- Remove Oil Strainer31
- Remove Valve Body31
- Remove O/D Case and Center Support Apply Gaskets32
- Remove Throttle Cable32
- Remove One-Way Clutch Retainer32
- Remove Solenoid Wiring33
- Check Thrust Clearance of Overdrive Input Shaft (Overdrive Planetary Gear)33
- Remove C2 Bo B2 Accumulator Pistons and Springs33
- Remove Oil Pump34
- Remove Overdrive Planetary Gear, Over-Drive Direct Clutch and One-Way Clutch Assembly34
- Remove Overdrive Planetary Ring Gear Assembly35
- Check Thrust Clearance of Input Shaft (Front Clutch Drum)35
- Remove Overdrive Case Assembly36
- Check Thrust Clearance of Center Support, and Remove Center Support Assembly37
- Remove Front Clutch Assembly37
- Remove Rear Clutch Assembly37
- Remove Speedsensor39
- Remove Transfer Adaptor and Output Shaft Rear Bearing39
- Remove Output Shaft Spacer40
- Remove Speed Sensor Rotor40
- Remove Planetary Gears, One-Way Clutch and Output Shaft Assembly40
- Check Piston Stroke of First and Reverse Brake Piston41
- Remove First and Reverse Brake Piston41
- Remove C, Accumulator Piston and Spring43
- Remove Transmission Rear Cover43
- Remove Manual Valve Lever, Shaft and Oil Seals43
- General Cleaning Notes45
- Parts Arrangement45
- General Assembly45
- Remove Oil Seal Rings46
- Components Disassembly46
- Use Torque Converter as Work Stand46
- Oil Pump Components46
- Remove Check Ball47
- Remove Eight Bolts and Pump Cover47
- Remove Oil Pump Drive and Driven Gears47
- Inspect Bushing of Oil Pump Body and Cover47
- Inspect Body Clearance of Driven Gear48
- Inspect Tip Clearance of Driven Gear48
- Inspect Side Clearance of Drive and Driven Gears48
- If Necessary, Replace Oil Seal49
- Oil Pump Assembly49
- Install Driven and Drive Gears to Oil Pump Body49
- Install Oil Pump Cover to Oil Pump Body49
- Install Check Ball50
- Install Oil Seal Rings50
- Check Oil Pump Drive Rotation50
- Overdrive Unit Components51
- Remove Flange, Plates and Discs52
- Check Operation of One-Way Clutch52
- Check Piston Stroke of Overdrive Direct Clutch52
- Overdrive Gear Unit Disassembly52
- Remove Piston Return Spring53
- Remove Overdrive Direct Clutch Piston53
- Remove Oil Seal Ring from Ring Gear Flange53
- Remove Ring Gear Flange53
- Remove One-Way Clutch from Overdrive Planetary Gear54
- Remove Ring Retainers55
- Check Piston Stroke of Overdrive Brake55
- Remove Flange, Discs and Plates55
- Remove Overdrive Brake Piston56
- Overdrive Unit Inspection57
- Inspect Discs, Plates and Flange57
- Inspect Bushings of Overdrive Direct Clutch Drum57
- Inspect Bushings of Overdrive Planetary Gear57
- Install One-Way Clutch to Overdrive Planetary Gear58
- Inspect Planetary Pinion Gear Thrust Clearance58
- Overdrive Unit Assembly58
- Inspect Bushing of Overdrive Case58
- Install Ring Gear Flange to Overdrive Planetary Ring Gear59
- Install Oil Seal Ring59
- Install Overdrive Direct Clutch Piston60
- Install Piston Return Spring60
- Install Plates, Discs and Flange60
- Install Overdrive Direct Clutch Assembly61
- Install Overdrive Brake Piston62
- Install Ring Retainers64
- Front Clutch Components65
- Front Clutch Disassembly65
- Place Front Clutch Assembly Onto Over-Drive Case Assembly65
- Remove Rear and Front Clutch Hubs65
- Check Piston Stroke of Front Clutch66
- Remove Oil Seal Ring67
- Remove Piston Return Springs67
- Remove Front Clutch Piston67
- Remove Discs, Plates and Cushion Plate67
- Front Clutch Inspection68
- Inspect Discs. Plates and Cushion Plate68
- Inspect Front Clutch Piston68
- Front Clutch Assembly68
- Install Front Clutch Piston69
- Install Piston Return Springs69
- Install Cushion Plate, Plates and Discs69
- Install Front and Rear Clutch Hubs70
- Rear Clutch Components72
- Rear Clutch Disassembly72
- Check Piston Stroke of Rear Clutch72
- Remove Rear Clutch Piston73
- Install Rear Clutch Piston74
- Rear Clutch Assembly74
- Inspect Rear Clutch Piston74
- Rear Clutch Inspection74
- Second Brake Components77
- Second Brake Disassembly77
- Remove Front Planetary Sun Gear77
- Check Piston Stroke of Second Brake78
- Remove Second Brake Piston79
- Second Brake Inspection79
- Inspect Bushing of Center Support80
- Inspect Bushings of Front Planetary Sun Gear80
- Second Brake Assembly80
- Install Second Brake Piston80
- Install Front Planetary Sun Gear82
- Front and Rear Planetary Gear Unit Components83
- Front and Rear Planetary Gear Unit Disassembly83
Gear Unita83
- Remove One-Way Clutch84
- Remove Output Shaft84
- Remove Rear Planetary Ring Gear and In-Termediate Shaft Assembly85
- Remove Rear Planetary Sun Gear85
- Remove Rear Planetary Ring Gear and Flange Assembly85
- Remove Rear Planetary Ring Gear Flange86
- Remove Front Planetary Ring Gear86
- Remove No.2 Thrust Washer87
- Remove O-Ring87
- Front and Rear Planetary Gear Unit Inspection87
- Inspect Bushing of Output Shaft87
- Front and Rear Planetary Gear Unit Assembly88
- Install O-Ring88
- Install No.2 Thrust Washer88
- Install Front Planetary Ring Gear88
- Install Rear Planetary Ring Gear and Flange Assembly89
- Install Output Shaft90
- Install Rear Planetary Ring Gear and Intermediate Shaft Assembly90
- Install Rear Planetary Sun Gear90
- Install One-Way Clutch91
- Install No.1 Rear Thrust Washer91
- First and Reverse Brake Components92
- First and Reverse Brake Inspection92
- Inspect Discs, Plates and Cushion Plate92
- Valve Body Components93
- Valve Body Disassembly94
- Remove Drain Tube94
- Remove Oil Tubes94
- Remove Manual Detent Spring94
- Remove Four Solenoid Valves95
- Remove Lower Valve Body Cover and Plate95
- Remove Two Plats95
- Separate Upper and Lower Valve Bodys95
- Install Lower Valve Body96
- Install Valve Body Plate96
- Valve Body Assembly96
- Install Upper Valve Body Installation Bolts97
- Install Two Plates97
- Install Lower Valve Body Plate and Cover97
- Tighten Bolts of Upper and Lower Valve Bodies98
- Install Four Solenoid Valves98
- Install Manual Detent Spring98
- Install Drain Tube99
- Install Oil Tubes99
- Install Manual Valve99
- Upper Valve Body Components100
- Valve Body Springs Specifications101
- Retainers and Pins102
- Check Balls103
- Lower Valve Body Components104
- Parts Locations106
- Retainers and Pins Lower Side106
- Upper Side107
- Check Valve, Ball and Springs108
- Strainers109
- Transmission Case Components110
- Transmission Case Inspection110
- Inspect Bushing of Transmission Case110
- If Necessary, Replace Output Shaft Front Bearing110
- Parking Lock Pawl Components111
- Parking Lock Pawl Disassembly111
- Remove Parking Lock Pawl Shaft111
- Remove Parking Lock Pawl Bracket112
- Parking Lock Pawl Assembly112
- Install Parking Lock Pawl Bracket112
- Install Parking Lock Pawl Shaft113
- General Installation Notes114
Component Parts Installation114
- Bearings and Races Location115
- Install Manual Valve Lever, Shaft and Oil Seals116
- Basic Subassembly Reassembly116
- Install Transmission Rear Cover117
- Install Accumulator Piston and Spring117
- Install First and Reverse Brake Piston118
- Check Piston Stroke of First and Reverse Brake120
- Install Planetary Gears, One-Way Clutch and Output Shaft Assembly120
- Install Speed Sensor Rotor121
- Install Output Shaft Spacers121
- Install Transfer Adaptor and Output Shaft Rear Bearing122
- Install Output Shaft Spacer122
- Install Output Shaft Rear Bearing Retainer122
- Install Speed Sensor123
- Temporarily Install Center Support Assembly123
- Adjust Thrust Clearance of Center Support123
- Install Center Support Assembly125
- Install Rear Clutch Assembly125
- Temporarily Install Overdrive Case Assembly126
- Check Correct Installation of Front Clutch Assembly126
- Install Front Clutch Assembly126
- Adjust Thrust Clearance of Input Shaft (Front Clutch Drum)127
- Install Overdrive Case Assembly128
- Install Overdrive Ring Gear Assembly129
- Install Overdrive Planetary Gear, Overdrive Direct Clutch and One-Way Clutch Assembly129
- Check Correct Installation of Overdrive Planetary Gear, Overdrive Direct Clutch and One-Way Clutch Assembly130
- Temporarily Install Oil Pump130
- Adjust Thrust Clearance of Overdrive Input Shaft (Overdrive Planetary Gear)131
- Install Oil Pump132
- Install C2, B0, B2 Accumulator Springs and Pistons133
- Install Throttle Cable133
- Install First and Reverse Brake Guide133
- Install Solenoid Wiring134
- Install Center Support Apply Gasket134
- Install Valve Body134
- Install Magnets in Pan135
- Install Oil Strainer135
- Connect Four Solenoid Connectors135
- Install Oil Pan136
- Install Transfer Assembly136
- Install Transmission Housing136
- Install Two Transmission Oil Cooler Unions136
- Install A/T Fluid Temperature Sensor137
- Install Control Shaft Lever137
- Install Neutral Start Switch137
- Install Breather Plug and Hose138
- Service Data139
Service Specifications139
- Upper Valve Body141
- Lower Valve Body141
- Spring Specifications141
- Retainers and Pins Specifications141
- Check Valve, Ball and Springs Specifications142
- Accumulator142
- Torque Specifications143