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Transmission Manual A440F, A440L

Repair Manual for Automatic Transmission

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Zilehasnain Master
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Transmission Manual A440F, A440L

Repair Manual for Automatic Transmission

Uploaded by

Zilehasnain Master
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
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TOYOTA A440F,A440L AUTOMATIC TRANSMISSION -REPAIR MANUAL Nov.,1984FOREWORD This repair manual has been prepared to provide information covering general service repairs for the Automatic Transmission with Overdrive, A440F and A440L transmissions. Applicable models: A440F — FJ62 series FJ70, 73 series All information contained in this manual is the most up-to-date at the time of publication. However specifications and pro- ‘cedures are subject to change without notice. TOYOTA MOTOR CORPORATIONTOYOTA AUTOMATIC TRANSMISSION A440F,A440L REPAIR MANUAL INTRODUCTION MX AUTOMATIC TRANSMISSION EX SERVICE SPECIFICATIONS [NM STANDARD BOLT TORQUE SPECIFICATIONS [GH SST AND SSM AUTOMATIC TRANSMISSION HYDRAULIC CIRCUIT [DH @ 1987 TOYOTA MOTOR CORPORATION All ight reserved ThE book ied, in whole “ Merthout the written permission of ‘Toyota Motor Corporation,INTRODUCTION HOW TO USE THIS MANUAL ........ GENERAL REPAIR INSTRUCTIONS - ABBREVIATIONS USED IN THIS MANUAL ..... Page IN-2 IN4 INS:INTRODUCTION — How to Use This Manual HOW TO USE THIS MANUAL To assist in finding your way through the manual, the Section Title and major heading are given at the top of every page. ‘An INDEX is provided on the 1st page of each section to guide you to the item to be repaired. At the beginning of each section, PRECAUTIONS are given that, pertain to al! repair operations contained in that section, Read these precautions before starting any repair task. REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: ee caving Je fA \ a y Rear Output Shaft Pun R Subassembly il Pump O00 ®: i Me _ 9 Oe” spacer Bearing From cue Sinembiyg peng Rete age — 4 OBE] * (5008/9 0 © O10 04 127] ‘Rear Companion Flange 195.014, 18), 175.013, 177 = Specified torque @ Non-reusabie part H_Precosted partINTRODUCTION — How to Use This Manual INS Mlustration: what to do and where ‘The procedures are presented in a step-by-step format: © The illustration shows what to do and where to do it. © The task heading tells what to do. © The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example: _—Task heading: what to do 21. CHECK PISTON STROKE OF OVERDRIVE BRAKE (a) Place SST and a dial indicator onto the overdrive brake piston as shown in the figure. SST 09350-30020 (09350-96120) Set‘part No. Component part No. Detail text: how to do it {b) Measure the stroke applying and releasing the com: pressed air (4 — 8 kg-cm? , 57 — 114 psi or 382 — 785 kPa) as shown in the figure. Piston stroke: 1.4 — 1.7 mm (0.055 — 0.067 in.) "Specification This format enables the experienced technician to have a FAST TRACK. He can read the task headings and only refer to the detailed text when he needs it. Important specifications and warnings always stand out in bold type. REFERENCES References have been kept to a minimum. However, when they are required you are given the page to go to. SPECIFICATIONS Specifications are presented in bold type throughout the text in ‘the applicable step, You never have to leave the procedure to Jook up your specs. All specifications are also found in Appen- dix A, specifications for quick reference. WARNINGS, CAUTIONS, NOTES: © WARNINGS are presented in bold type, and indicate there is a possibility of injury to you or other people. @ CAUTIONS are also presented in bold type, and indicate the possibility of damage to the components being repaired © NOTES are separated from the text but do not appear in bold. They provide additional information to help you efficiently perform the repair.IN4 INTRODUCTION — General Repair Instructions GENERAL REPAIR INSTRUCTIONS Seal Lock Adhesive 1 10. nn. Use fender, seat and floor covers to keep the vehicle clean and prevent damage. During disassembly, keep parts in order to facilitate reas- sembly. Before performing electrical work, disconnect the cable from the battery terminal. Check hose and wiring connectors to make sure that they are secure and correct. Non-reusable Parts (a) Always replace cotter pins, gaskets, O-rings and oil seals etc, with new ones. {b) Non-reusable parts illustrations by the ” re indicated in the component ‘@” symbol. Precoated Parts Precoated parts are the bolts, nuts, etc. which are coated with a seal lock adhesive at the factory, (a) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. (b) Recoating of Precoated Parts (1) Clean off the old adhesive from the bolt, nut or installation part threads. (2) Dry with compressed air. (3) Apply the specified seal lock adhesive to the bolt or nut threads. (c)_ Precoated parts are indicated in the component illust: rations by the “k"" symbol. When necessary, use a sealer on gaskets to prevent leaks. Carefully observe all specifications for bolt tightening tor- ques. Always use a torque wrench, Use of special service tools (SST) and special service mate rials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure. A list of SST and ‘SSM can be found at the back of this manual. When replacing fuses, be sure the new fuse is the correct amperage rating. DO NOT exceed the fuse amp rating or se one of a lower rating. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the pro- per locations. {a) If the vehicle is to be jacked up only at the front or rear end, be sure to block the wheels to ensure safety. (b) After the vehicle is jacked up, be sure to support it on stands, It is extremely dangerous to do any work on. the vehicle raised on jack alone, even for a small jobINTRODUCTION — Abbreviations Used in This Manual INS ABBREVIATIONS USED IN THIS MANUAL ATF ‘Automatic Transmission Fluid Bo Overdrive Brake Ba Second Brake Ba First and Reverse Brake Co Overdrive Direct Clutch Front Clutch Ca Rear Clutch D Disc Ex, Except Fo Overdrive One-way Clutch Fa No. 2 One-way Clutch oD Overdrive Pp Plate SSM Special Service Materials ssT ‘Special Service Tools STD Standard wi With wio WithoutATA AUTOMATIC TRANSMISSION Page DISASSEMBLY OF TRANSMISSION (A440F) .. AT.2 DISASSEMBLY OF TRANSMISSION (A440L) .. AT.17 COMPONENT GROUP DISASSEMBLY, INSPECTION AND ASSEMBLY NOTES AT-27 MANUAL VALVE LEVER AND SHAFT AT-28 PARKING LOCK PAWL (A440F) AT31 PARKING LOCK PAWL (A440L) AT-34 EXTENSION HOUSING (A440L) AT-36 OWL PUMP oe - AT-37 OVERDRIVE PLANETARY GEAR AND OVERDRIVE DIRECT CLUTCH (co) AT-42 OVERDRIVE SUPPORT AT-50 FRONT CLUTCH (Ci) AT-55 REAR CLUTCH (C2) ATI CENTER SUPPORT .. ; AT-65 PLANETARY GEAR AND OUTPUT SHAFT (A440F) oo... AT-69 PLANETARY GEAR AND OUTPUT SHAFT (A440L) sees AT-76 FIRST AND REVERSE BRAKE (Bs) .......... AT-82 GOVERNOR VALVE ASSEMBLY .. AT87 VALVE BODY : AT-92 Disassembly of Valve Body . AT-92 Front Upper Valve Body . AT-96 Rear Upper Valve Body . AT-102 Lower Valve Body ..... AT-111 Assembly of Valve Body ...... sees ATA21 ASSEMBLY OF TRANSMISSION (A440F) AT-125 ASSEMBLY OF TRANSMISSION (A440L) ..... AT-147sion (A440F) sassembly of Trans AUTOMATIC TRANSMISSION — DISASSEMBLY OF TRANSMISSION (A440F) COMPONENTS Lock Washer 79 (69 mb, 77) Oil Filler Gauge (are | il Filler Tube o > iG @ORIng AT2 Noutral Start Switch Control Shaft Lever Spacer Spacer | ‘Transmission Housing Governor Body L4 Position Switch Spacer | Neutral Position Torque Converter Speedometer Drive Geer | —_Suwitch | Washer Eront Drive Shift Fork. 4 Shaft Subessembly e Bearing Retainer: oar Output Shaft Assembly: ‘Transfer Input Gear Power Take-off Drive Gear Transfer Front Cote ASIST RNS OOD ne Q | Wosher ater Gear Shaft Bearing Bearing | Thrust Washer Spacer Idler Gear 0-4 O-Ring > x(a pam) [scour sa] ¢ 400 (29, 39) SP foie Lock Plate $ORina Gasket, No.2 Case Cover Shift Plug. Spring a Locking Ball —$ ’ Theust Washer carat ‘Transfer Rear Case o fr Gasket Power Take-off Cover Bearing Retainer ‘O Gasket ' B—F Look Nut Washer | 765 113, 18) % Rear Companion | [Kerem (ietb, Nem] : Specified torque 75 (13,7) O-Ring Flange © Non-reusable part Speedometer Driven Gear Ik Precoated part anesAUTOMATIC TRANSMISSION — Disassembly of Transmission (A440F) ATS COMPONENTS (Cont'd) Front Cutch Accumulator Cover Plate ‘st and Rev. Brake Piston Ist and Rev, Brake sembly, Planetary Gear and Output Shaft Snap Ring Snap Ring & ‘Transmission Rear cover" Gasket Spring 4 Transmission Case J sme ale = Istand Rew. Brake turn Spring Assembly. Center Support comes fone | Front Clutch | Rcemoly Race ) ‘Theust Bearing Ring Gest” | Thrust Bearing OD Direot Drain Plug Clutch’ Assembly @ Nonreusable part ousATA AUTOMATIC TRANSMISSION — Disassembly of Transmission (A440F) SEPARATE BASIC SUBASSEMBLY 1. REMOVE TORQUE CONVERTER 2. REMOVE OIL FILLER GAUGE AND TUBE 3. REMOVE CONTROL SHAFT LEVER 4. REMOVE NEUTRAL START SWITCH {a) Loosen the lock washer claw and remove the nut. {b) Remove the lock washer and grommet. {c) Remove the two bolts and neutral start switch. 5. REMOVE TRANSFER NEUTRAL SWITCH AND TRANSFER L4 POSITION SWITCH (a) Disconnect the three connectors. (b) Remove the transfer neutral position switch. (c)_ Remove the transfer L4 position switch.7. ATS REMOVE TRANSMISSION HOUSING (a) Remove the throttle cable retaining plate, {b) Remove the eight bolts and transmission housing, REMOVE SPEEDOMETER DRIVEN GEAR (a) Remove the lock plate. {b) Remove the speedometer driven gear. (c)_ Remove the O-ring from the speedometer driven gear. REMOVE POWER TAKE-OFF COVER Remove the six bolts, and remove the power takeoff cover and gasket. REMOVE TRANSFER NO.2 CASE COVER Remove the six bolts and remove the transfer No. 2 case cover and gasket.ATS AUTOMATIC TRANSMISSION — Disassembly of Transmi n (A440F) 10. REMOVE TRANSMISSION OUTPUT SHAFT LOCK NUT. (a) Using a hammer and chisel, loosen the stacked part of the nut, (b) Using SST to hold the rear companion flange, remove the transmission output shaft lock nut and washer. SST 09330-00021 11, REMOVE REAR COMPANION FLANGE (a) Using a hammer and chisel, loosen the stacked part of the nut. {b) Using SST to hold the rear companion flange, remove ‘the companion flange lock nut and washer. SST 09330-00021 (c) Remove the rear companion flange. 12. REMOVE REAR OUTPUT SHAFT BEARING RETAINER Remove the six bolts and remove the rear output shaft bearing retainer and gasket.AUTOMATIC TRANSMISSION — Disassembly of Transmission (A440F) AT] 13, REMOVE WASHER, SPEEDOMETER DRIVE GEAR AND SPACER 14. REMOVE IDLER GEAR SHAFT LOCK PLATE 15. REMOVE SHIFT PLUG Remove the shift plug and using a magnetic finger, remove the spring and locking ball. 16. REMOVE TRANSFER REAR CASE (a) Remove the fourteen bolts. (b) Using a plastic hammer, remove the transfer rear case. (c} Remove the gasket from the transfer front case. (d)_ Remove the thrust washer from idler gear shaft.ATS AUTOMATIC TRANSMISSION — Disassembly of Transmi jion (A440F) 17. REMOVE REAR OUTPUT SHAFT ASSEMBLY WITH FRONT DRIVE SHIFT FORK SHAFT SUBASSEMBLY 18. REMOVE POWER TAKE-OFF DRIVE GEAR (a) Using SST, remove the transfer input gear bearing SST 09950-20016 (b) Remove the power take-off gear. (c) Remove the spacer. 19, REMOVE TRANSFER INPUT GEAR (a) Using SST, remove the transfer input gear. SST 09950-20016 (b) Remove the O-ring from transmission output shaft.Al UTOMATIC TRANSMISSION — Disassembly of Transmission (A440F) AT 20. REMOVE IDLER GEAR, BEARING, SPACER AND IDLER GEAR SHAFT (2) Remove the O-ring from the idler gear shaft. () Remove the idler gear with the two bearings and spacer. {c) Remove the two bearings and spacer from the idler gear. (4) Remove the thrust washer from idler gear shaft. 21. REMOVE REAR OUTPUT SHAFT FRONT BEARING RETAINER Remove the rear output shaft front bearing retainer from the transfer front case.AUTOMATIC TRANSMISSION 22, 23. 24, isassembly of Transmission (A440F) REMOVE TRANSFER FRONT CASE (a) Remove the four bolts and using a plastic hammer, remove the transfer front case. {b) Remove the gasket and spacer. REMOVE TRANSMISSION REAR BEARING {a} Remove the ten transfer adapter installation bolts. (b) Using SST, remove the transfer adapter with trans- mission rear bearing. SST 09350-36010 (09350-06140) {c) Remove the gasket. REMOVE GOVERNOR BODY (a) Remove the spacer from the transmission output shaft, (b) Remove the governor body.AUTOMATIC TRANSMISSION — Disassembly of Transmission (A440F) 25. REMOVE OIL PAN (a) Position the oil pan so it does not tilt upright. (b) Remove the twenty bolts and remove the oil pan and gasket. CAUTION: © Do not dent the oil pan, © Do not turn the transmission over, as this will contar nate the valve body with the foreign materials in the bottom of the pan. 26. EXAMINE PARTICLES IN PAN Remove the magnet and use it to collect any steel chips. Examine the chips and particles in the pan and on the Magnet to anticipate what type of wear you will find in the transmission. Steel (magnetic)...bearing, gear and clutch plate wear Brass (non-magnetic}...bushing wear 27. REMOVE OIL TUBE (a) Remove the lock up relay valve body plate. NOTE: Do not drop the lock up relay valve pins. (b) Pry up both tube ends with the large screwdriver and remove the oil tube. (c) Temporarily install the lock up relay valve body plate with four short bolts, 28. REMOVE OIL STRAINER Remove the ten bolts and remove the oil strainer and gasket.Al \UTOMATIC_TRANSMISSION — Disassembly of Transmission (A440F) 29, 31. 32. REMOVE VALVE BODY (a) Remove the fifteen bolts. (b) Disconnect the throttle cable from the cam. {c)_ Remove the valve body from the transmission case. REMOVE FOUR TRANSMISSION CASE APPLICATION GASKETS REMOVE THROTTLE CABLE Using 10-mm socket, push the plastic throttle cable re- tainer, out of the transmission case. REMOVE C: ACCUMULATOR PISTON AND SPRING Applying compressed air to. the oil hole, remove the Cz accumulator piston and spring as shown in the figure.34, 35. 33. REMOVE B, AND B, SPRINGS Applying compressed air to the oil hole, remove the By and 8; accumulator pistons and two springs as shown in the figure, ACCUMULATOR PISTONS AND REMOVE C: ACCUMULATOR PISTON AND SPRING (2) Remove the four bolts and remove the front clutch accumulator cover. (b) Remove the plate and two gaskets. {c)_ Applying compressed air to the oil hole, remove the C1 accumulator piston and spring as shown in the figure. REMOVE OIL PUMP (a) Place matchmarks on the oil pump body and trans- mission case. (b) Remove the eleven bolts. {c)_ Using SST, pull off the oll pump from the transmis: sion case. ‘SST 09350-36010 (09350-08140)AUTOMATIC TRANSMISSION 36. 37. 39. ion (A440F) sssembly of Transmi {d) Remove the race and O-ring. MEASURE DISTANCE BETWEEN TOP OF CASE AND CLUTCH DRUM Set SST on the case as shown in the figure. ‘SST 09350-36010 (09350-06090) Make a note of the distance for assembly. REMOVE OVERDRIVE DIRECT CLUTCH AND OVER- DRIVE PLANETARY GEAR Grasp the shaft and pull out the overdrive direct clutch and overdrive planetary gear. Watch for bearings and races on both sides of assembly. REMOVE OVERDRIVE PLANETARY RING GEAR Watch for bearing and races on both sides of assembly. REMOVE OVERDRIVE SUPPORT {a) Using a screwdriver, remove the snap ring,AUTOMATIC TRANSMISSION — Disassembly of Transmission (A440F} ATS (b) Remove the three overdrive support lock bolts, 5 {c)__ Using SST, remove the overdrive support. ¢ SST 09360-36010 (09350-06140) {d) Remove the three O-rings from the overdrive support. 40. MEASURE DISTANCE BETWEEN TOP OF CASE AND CLUTCH DRUM Set SST on the case as shown in the figure. SST 09360-36010 (09350-06090) Mark the note of the distance for assembly. 41, REMOVE FRONT CLUTCH ASSEMBLY Remove the front clutch assembly from the rear clutch. Watch for bearing and races on both sides of assembly. 42, REMOVE REAR CLUTCH ASSEMBLY Insert two wire hooks into flukes of the clutch disc and remove the rear clutch assembly.AUTOMATIC TRANSMISSION — Disassembly of Transmission (A440F) 43. REMOVE CENTER SUPPORT (a) Remove the three center support lock bolts. {b) Using SST, remove the center support. SST 09360-36010 (09350-06140) (c) Remove the three O-rings from the center support. 44, REMOVE PLANETARY GEAR AND OUTPUT SHAFT (a) Using a screwdriver, remove the snap ring. (b) Remove the planetary gear and output shaft with the one-way clutch. 45, REMOVE TRANSMISSION REAR COVER Remove the three bolts and six screws and remove the transmission rear cover and gasket.AUTOMATIC TRANSMISSION — Disassembly of Transmission (A440L) AT-7 DISASSEMBLY OF TRANSMISSION (A440L) COMPONENTS (seorar.ear) a8) Transmission Housing Torque Converter Olt Pump Oi Filer Tube © O-Ring Lock Plate FO x @ 0-Ring —O' Speedometer Driven Gear Speedometer Drive Gear | Spicer @ Gasket Snap Ring Governor Body [kom tietb, NanT] + Specified torque @ _Non-reusable portAUTOMATIC TRANSMISSION — Disassembly of Transmission (A440L) AT-18 COMPONENTS (Cont'd) Front clutch Accumulator Cover O-Ring oon ws sy? J | Ist and Rev.

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