Toyota A442F Operating instructions

IN-1
INTRODUCTION
HOWTOUSETHISMANUALIN-2
GENERALREPAIRINSTRUCTIONSIN-5
ABBREVIATIONSUSEDINTHIS
MANUALIN-7
STANDARDBOLTTORQUE
SPECIFICATIONSIN-8

IN-2INTRODUCTION- HOWTOUSETHISMANUAL
HOWTOUSETHISMANUAL
INOO2-OC
Toassistyouinfindingyourwaythroughthemanual,theSectionTitleandmajorheadingare
givenatthetopofeverypage.
PREPARATION
PreparationliststheSST(SpecialServiceTools),recommendedtools,equipment,lubricantand
SSM(SpecialServiceMaterials)whichshouldbepreparedbeforebeginningtheoperationand
explainsthepurposeofeachone.
REPAIRPROCEDURES
Mostrepairoperationsbeginwithanoverviewillustration.Itidentifiesthecomponentsand
showshowthepartsfittogether.
Example:
OilPumpCover
OilPumpDriveGear
OilPumpBody
OilSeal
OilPumpDrivenGear
Specifiedtorque
OilSealRing
SpringSeat
Spring
CheckBall
Non-reusablepart

INTRODUCTION- HOWTOUSETHISMANUALIN-3
Theproceduresarepresentedina step—by—stepformat:
•Theillustrationshowswhattodoandwheretodoit.
•Thetaskheadingtellswhattodo.
•Thedetailedtexttellshowtoperformthetaskandgivesotherinformationsuchas
specificationsandwarnings.
Example:
Thisformatprovidestheexperiencedtechnicianwitha FASTTRACKtotheinformationneeded.
Theuppercasetaskheadingcanbereadata glancewhennecessary,andthetextbelowit
providesdetailedinformation.Importantspecificationsandwarningsalwaysstandoutinbold
type.
REFERENCES
Referenceshavebeenkepttoa minimum.However,whentheyarerequiredyouaregiventhe
pagetoreferto.
SPECIFICATIONS
Specificationsarepresentedinboldtypethroughoutthetextwhereneeded.Youneverhaveto
leavetheproceduretolookupyourspecifications.TheyarealsofoundatthebackofATsection,
forquickreference.

IN-4INTRODUCTION- HOWTOUSETHISMANUAL
CAUTIONS,NOTICES,HINTS:
•CAUTIONSarepresentedinboldtype,andindicatethereisa possibilityofinjurytoyouor
otherpeople.
•NOTICESarealsopresentedinboldtype,andindicatethepossibilityofdamagetothe
componentsbeingrepaired.
•HINTSareseparatedfromthetextbutdonotappearinbold.Theyprovideadditional
informationtohelpyouperformtherepairefficiently.
SIUNIT
TheUNITSgiveninthismanualareprimarilyexpressedaccordingtowiththeSIUNIT(Inter-
nationalSystemofUnit),andalternatelyexpressedinthemetricsystemandintheEnglish
System.
Example:
Torque:30Nm(310kgf-cm,22ftlbf)

INTRODUCTION- GENERALREPAIRINSTRUCTIONSIN-5
GENERALREPAIRINSTRUCTIONS
1.Usefender,seatandfloorcoverstokeepthevehicle
cleanandpreventdamage.
2.Duringdisassembly,keeppartsintheappropriate
ordertofacilitatereassembly.
3.Observethefollowing:
(a)Beforeperformingelectricalwork,disconnect
thenegativecablefromthebatteryterminal.
(b)Ifitisnecessarytodisconnectthebatteryfor
inspectionorrepair,alwaysdisconnectthecable
fromthenegative(—)terminalwhichisgrounded
tothevehiclebody.
(c)Topreventdamagetothebatteryterminalpost,
loosentheterminalnutandraisethecablestr-
aightupwithouttwistingorpryingit.
(d)Cleanthebatteryterminalpostsandcableter-
minalswitha cleanshoprag.Donotscrapethem
witha fileorotherabrasiveobjects.
(e)Installthecableterminaltothebatterypostwith
thenutloose,andtightenthenutafterinstalla-
tion.Donotusea hammertotaptheterminal
ontothepost.
(f)Besurethecoverforthepositive(+) terminalis
properlyinplace.
4.Checkhoseandwiringconnectorstomakesurethat
theyaresecureandcorrect.
5.Non—reusableparts
(a)Alwaysreplacecotterpins,gaskets,O—ringsand
oilsealsetc.withnewones.
(b)Non—reusablepartsareindicatedinthecom-
ponentillustrationsbythesymbol.
6.Precoatedparts
Precoatedpartsareboltsandnuts,etc.thatare
coatedwitha seallockadhesiveatthefactory.
(a)Ifa precoatedpartisretightened,loosenedor
causedtomoveinanyway,itmustberecoated
withthespecifiedadhesive.

INTRODUCTION- GENERALREPAIRINSTRUCTIONS
(b)Whenreusingprecoatedparts,cleanofftheold
adhesiveanddrywithcompressedair.Then
applythespecifiedseallockadhesivetothebolt,
nutorthreads.
(c)Precoatedpartsareindicatedinthecomponent
illustrationsbythesymbol.
7.Whennecessary,usea sealerongasketstoprevent
leaks.
8.Carefullyobserveallspecificationsforbolttightening
torques.Alwaysusea torquewrench.
9.Useofspecialservicetools(SST)andspecialservice
materials(SSM)mayberequired,dependingonthe
natureoftherepair.BesuretouseSSTandSSM
wherespecifiedandfollowtheproperworkproce-
dure.A listofSSTandSSMcanbefoundatthe
preparationofATsection.
10.Whenreplacingfuses,besurethenewfusehasthe
correctamperagerating.DONOTexceedtheratingor
useonewitha lowerrating.
11.Caremustbetakenwhenjackingupandsupporting
thevehicle.Besuretoliftandsupportthevehicleat
theproperlocations.
(a)Ifthevehicleistobejackeduponlyatthefront
orrearend,besuretoblockthewheelsatthe
oppositeendinordertoensuresafety.
(b)Afterthevehicleisjackedup,besuretosupport
itonstands.Itisextremelydangeroustodoany
workona vehicleraisedona jackalone,evenfor
asmalljobthatcanbefinishedquickly.

INTRODUCTION- ABBREVIATIONSUSEDINTHISMANUALIN-7
ABBREVIATIONSUSEDINTHIS
MANUAL
AutomaticTransaxleFluid
OverdriveBrake
2ndBrake
1standReverseBrake
OverdriveDirectClutch
FrontClutch
RearClutch
Disc
Except
Flange
OverdriveOne—wayClutch
No.2One-wayClutch
Multipurpose
Overdrive
Plate
SpecialServiceMaterials
SpecialServiceTools
with

IN-8INTRODUCTION- STANDARDBOLTTORQUESPECIFICATIONS
STANDARDBOLTTORQUESPECIFICATIONS
HOWTODETERMINEBOLTSTRENGTH
Hexagon
headbolt
Hexagon
flangebolt
w/washer
hexagonbolt
Nomark
Hexagon
headboltTwo
protruding
lines
Nomark
Hexagon
flangebolt
w/washer
hexagonbolt
Two
protruding
lines
Hexagon
headbolt
Three
protruding
lines
Hexagon
headbolt
Four
protruding
lines
Weldedbolt
Grooved
Studbolt
Nomark

INTRODUCTION- STANDARDBOLTTORQUESPECIFICATIONSIN-9
SPECIFIEDTORQUEFORSTANDARDBOLTS

MEMO

AT-1
AUTOMATICTRANSMISSION
DESCRIPTIONAT-2
OPERATIONAT-4
PREPARATIONAT-10
COMPONENTPARTSREMOVALAT-13
OILPUMPAT-33
OVERDRIVEUNITAT-38
FRONTCLUTCHAT-52
REARCLUTCHAT-59
SECONDBRAKEAT-64
FRONTANDREARPLANETARY
GEARUNITAT-70
FIRSTANDREVERSEBRAKEAT-79
VALVEBODYAT-80
UPPERVALVEBODYAT-87
LOWERVALVEBODYAT-91
TRANSMISSIONCASEAT-97
PARKINGLOCKPAWLAT-98
COMPONENTPARTSINSTALLATIONAT-101
SERVICESPECIFICATIONSAT-126

AT-2AUTOMATICTRANSMISSION- DESCRIPTION
DESCRIPTION
GENERAL
ThenewA442Fautomatictransmissionisa 4—speedElectronicControlledAutomaticTrans-
missionandhasfollowingfeatures;
Electroniccontrolprovidesshiftandlock—uppointsmostappropriateforthepowercharac-
teristicsofeachengineandimprovesshiftresponse.
Ahigh—performancesuperflowtorqueconverterisusedtoimprovestartingoff,acceleration
andfueleconomy.
Foreasieroperation,theshiftleverpositionshavebeenreducedfrom7 (P,R,N,D,3,2,L)tothe6
positions(P,R,N,D,2,L)usedinpassengervehicles,andanO/Dmainswitchhasbeenprovidedon
theshiftlever.
Onvehiclesusingthe1FZ—FEengine,shiftresponsehasbeengreathlyimprovedbycommu-
nicationbetweentheEngineECUandECTECUtomomentarilyreduceengineoutputwhen
shifting.

AT-3
AUTOMATICTRANSMISSION- DESCRIPTION
GENERALSPECIFICATIONS
TypeofTransmission
TypeofEngine
TorqueConverterStallTorqueRatio
Lock—upMechanism
GearRatio1stGear
2ndGear
3rdGear
O/DGear
ReverseGear
NumberofDiscsandPlates
(DiscandPlate)
FrontClutch(C,)
RearClutch(C2)
O/DDirectClutch(Co)
2ndBrake(B2)
standReverseBrake(B3)
O/DBrake(Bo)
ATFType
A442F
1FZ-FE
1.8:1
Equipped
2.950
1.530
1.000
0.765
2.678
6/6
5/5
3/3
5/5
6/6
3/3
15.0(15.9,13.2)
6.0(6.3.5.3)
1HD-T
2.0:1
7/7

AT-4AUTOMATICTRANSMISSION- OPERATION
OPERATION
OPERATINGCONDITIONS

AT-5
AUTOMATICTRANSMISSION- OPERATION
FUNCTIONOFCOMPONENTS

AT-6AUTOMATICTRANSMISSION- OPERATION
Theconditionofoperationforeachgearpositionareshownonthefollowingillustration:

AT-7
AUTOMATICTRANSMISSION- OPERATION