[Cruiser Jimmy]

Fellows, I've decided to rebuild my tranny myself for the education.

The below is a narrative of an email to Rodney in OZ about the tranny.

The trans (A440F) has been acting weird lately for the past 6 days and it's finally come to a head. For the past 5 days the trans felt like it "released" the engine before it would upshift from 2nd to 3rd. By "released" I mean that the engine would rev say from 3500 rpms up to 4500 rpms before the trans would step into 3rd gear.
Well yesterday, the trans does not want to upshift to 3rd gear. I have to feather the gas to find 3rd, but that's only momentary.
At the same time I have checked reverse and found that I have to go to full throttle for reverse to kick in, otherwise I can go to 1/4 throttle before the rigs ever starts to move.

History of the Trans:
About three years ago the trans was rebuilt by a local tranny shop.
It over heated [A/T Oil Temp light] on 2 or 3 separate occasions after the rebuild and I replaced the fuild every time it over heated. Then I bought a tranny cooler from AutoZone and installed, the largest square inch I could find.
Not that this has anything to do with the trans operation, but the speedo cable broke last week the same time the trans started acting up. I just replaced the speedo cable last night.
Additionally, I was wheeling about a month ago and this hill was giving me hell. On four occations I got to the top of the hill and the rigs was rev'ing but not going anywhere. (wonder if I burnt something, ya' think)


Well, Rodney came back and basically stated what I suspected, the 3rd gear clutch is burnt, 3rd clutch also controls reverse operations.

So I've started the operation and will be replacing the clutches once I pick them up.

By the way, I bought the A440F rebuilt book from Toyota. That's the first thing one should do.

Future search requests:
Tranny rebuild
Transmission rebuild
Rebuild transmission

Here's a MUD salute to the operation.

[Cruiser Jimmy]

Here's one with the tranny fully disassembled.

Wish me luck.


Edit 12-29-05:
Disassembly is pretty easy. Take out the 11 bolts that hold the ATF oil pump to the body, take out the six bolts that hold the two brake housing in place in the body and everything else just comes right out.

You'll have a little trouble taking the oil pump out if you don't have a special tool. This is easily overcome by placing two bolts on the oil pump (used for pulling it out with the SST) and rotating it until it breaks free.

Once the pumps out just start taking the components out.

[peebles24]

Jim dosen't that require special tools. I know the chevy trannies I've rebuilt do. Oh and by the way good luck, if you need some help give me a holler. I will come if the wife will let me off the leash.

Chad

[Cruiser Jimmy]

Originally Posted by peebles24

Jim dosen't that require special tools. I know the chevy trannies I've rebuilt do. Oh and by the way good luck, if you need some help give me a holler. I will come if the wife will let me off the leash.

Chad

Yeah it does. I have tried to get them from the Sealership but they say it's only a purchase for the service guys. Most of the special tools I need are for attachments to a dial indicator, but two or three special tools are for compressing springs. If I can't get the springs off, I'll have them made by a local machine shop, that's my only option.

[landtank]

I know that Slee offers a swap for Rodneys transmissions with the modified valve body. Was that option considerably more than what you're doing here?

[Cruiser Jimmy]

Here's the problem.

These clutches are from the Brake Band & Multi-Disc Clutch (or Clutch C2 when looking at the manual.) These clutches should have material on it. Guess that's way I had no up shift.

[Cruiser Jimmy]

Originally Posted by landtank

I know that Slee offers a swap for Rodneys transmissions with the modified valve body. Was that option considerably more than what you're doing here?

Yes, it was a serious consideration. I wanted to buy an Extreme tranny/valve body from Rodney but my wallet had other plans.

The rebuild kit from "Axiom" is sub $1K for all seals, gaskets, clutches and steel plates.

[Benji]

One brave man, good luck. If you need help, give me a hollar.

[Rich]

http://toyota.spx.com is where to get the toyota special tools.

[Cruiser Jimmy]

Here's the first measurement:

Using a dial indicator, measure the thrust clearance of the input shaft
Standard thrust clearance: 0.40-0.90mm

My result: 1.1mm

[Cruiser Jimmy]

Originally Posted by Rich

http://toyota.spx.com is where to get the toyota special tools.

Rich,
Thanks so much. My two local Stealerships did not give me any value added information. One would not give me the information and the other did not know what I was talking about, "SST. . . What's an SST"
I hope he was new!!!

[Cruiser Jimmy]

Here's a shot of a steel plate. It must be replaced.

[cruiserdan]

Regretably the SST's he inquired about are discontinued.

[Cruiser Jimmy]

Originally Posted by cruiserdan

Regretably the SST's he inquired about are discontinued.

CD, Even the SST kit that's on SPX?

[Cruiser Jimmy]

Here are all the clutches

Edit 12-29-05:

The three sets of smaller clutches are what hold preasure to the gearing. The larger clutches are for braking when changing gearing.

[IdahoDoug]

Awesome. Simply awesome.

DougM

[absurdum80]

Great pics, keep us posted.

One question - doesn't the tranny weigh a ton?
How'd you get it in your workspace to begin with?

g.

[baxter650]

3 years on a rebuild, i hope you at least gave them a call to tell them they suck at rebuilding.

[cruiserdan]

Originally Posted by jklubens

CD, Even the SST kit that's on SPX?

If it's the 09350-36010-01 yes, it is discoutinued.

[Rich]

Originally Posted by cruiserdan

Regretably the SST's he inquired about are discontinued.

Bummer.

Lubens, I'd suggest that you call the contact number at SPX. They are not a Toyota company. They are a partner of Toyota. OTC is a tool manufacturer that SPX acquire, and they make general purpose automotive tools in addition to the special tools they manufacture for a number of auto companies. It is possible that for some of the Toyota SSTs they may have an OTC version that may be sufficiently similiar to get the job done.

[beno]

WOW...talk about DIY Jimmy.

So, is your rig going to be ready for Toys for Tots?

I assume 'no write up needed' on this one, as the tranny rebuild text is a good one?

What's your time frame for this?

Really nice.
Best.
-onur
Akron, OH

[cruiser larry]

Jim it looks like you are well on your way.it I can be of any help let me know and I will come up.

[Cruiser Jimmy]

Originally Posted by absurdum80

Great pics, keep us posted.

One question - doesn't the tranny weigh a ton?
How'd you get it in your workspace to begin with?

g.

Yes, the tranny does weigh a lot but i managed.
I've got a small storage room off the garage that is an ideal place for controlling dust. I closed the heater vent and used that space.

[Cruiser Jimmy]

Rich,
Thanks for the info. I noticed they are in Warren, MI so I assumed Toyota may farm this out.

Onur,
I am planning to be finished before Thanksgiving, with testing and all. By next weekend I should have it back together and at least under the rig.

Larry,
Thanks for the offer, but don't take time away from your engine problem.

[Cruiser Jimmy]

Originally Posted by baxter650

3 years on a rebuild, i hope you at least gave them a call to tell them they suck at rebuilding.

Well, most of the problem is my fault. I was persistent with a couple hills in the past years that I would not let them beat me.

But the most satisfaction I'll get is that I rebuilt a auto tranny myself.

[sjpitts]

Originally Posted by cruiserdan

If it's the 09350-36010-01 yes, it is discoutinued.

So does this mean we won't be able to get our trannies rebuilt?

One thing that bugs me about the thought of owning my 93 80 for the next 30 years is the prospect that I could need a tranny rebuilt and not be able to find a competent person to do it. After all, the tranny in my 80 was only available in the US for two years. So how many could have been sold? How much experiance is out there?

Compared to the turbo 350 in my FJ55 anyway. I will always be able to find someone to rebuild one of those.

Jared

[Cruiser Jimmy]

I just got off the phone with SPX OTC and individual parts are available for order. I only asked about two parts (pricing next to them). I went ahead and ordered the 06060-01 part. The other parts (Check ball spring compressor) I will be fabricating at home with are peice of bar stock.

Info below is for future search requests:

1991 1992 A440F Transmission Special Service Tools:

Part Number____Description
09350-36010-01 Master Kit for A440F Tranny SST.
09350-06010-01 NO. 2 PISTON SPRING COMPRESSOR
09350-06020-01 NO. 3 PISTON SPRING COMPRESSOR
09350-06030-01 NO. 1 PISTON SPRING COMPRESSOR
09350-06040-01 OIL SEAL REPLACER
09350-06050-01 HANDLE
09350-06060-01 TRANSMISSION REAR BEARING REPLACER $31
09350-06070-01 EXTENSION HOUSING BEARING REMOVER
09350-06080-01 EXTENSION HOUSING BEARING REPLACER
09350-06090-01 PLATE
09350-06100-01 CHECK BALL SPRING COMPRESSOR $75.24
09350-06110-01 NO. 1 MEASURING TERMINAL
09350-06120-01 NO. 2 MEASURING TERMINAL
09350-06130-01 EXTENSION BAR
09350-06140-01 OIL PUMP PULLER
09350-06150-01 OIL SEAL REPLACER

How to order:
Phone 1-800-933-8335
Business Hours:
8:00 am - 6:00 pm EST
Fax 1-800-578-7375
or
1-586-578-7375
Mail SPX Corporation, OTC
28635 Mound Road
Warren, MI 48092-3499

[IdahoDoug]

Jared,

Serious maintanance on your rig will prevent the need for a rebuild. My bro in law's got 293,000 miles on his untouched tranny. I think JK's being too kind to his rebuilder. With the smaller engine in his FJ80 and the heavy duty transmission, there's just about no way he should have been able to damage it in proper shape. This exact tranny was used for years in a 30,000lb GVW city bus in Japan. It's tough as nails, but can be defeated with poor maintenance just like any mechanical device from a bicycle to an Abrams tank.

DougM

[Cruiser Jimmy]

Got the following information from this web site HowStuffworks




"Automatic Transmission Fluid Oxidation
Automatic transmission fluid will provide 100,000 miles of service before oxidation occurs under normal operating temperatures of about 170°F. Above normal operating temperatures, the oxidation rate doubles (useful life of fluid is cut in half) with each 20° increase in temperature.

The approximate life expectancy at various temperatures is as follows:


175°F 100,000 miles
195°F 50,000 miles
212°F 25,000 miles
235°F 12,000 miles
255°F 6,250 miles
275°F 3,000 miles
295°F 1,500 miles
315°F 750 miles
335°F 325 miles
355°F 160 miles
375°F 80 miles
390°F 40 miles
415°F Less than 30 minutes


This information clearly shows why transmission oil coolers and the various maintenance intervals are recommended for severe usage.

Above 300°F, the metals inside the transmission will warp and distort in varying degrees depending on the severity of overheat. Because this damage occurs and fluid life is so seriously impaired, rocking out of snow, mud or sand should never exceed a very few minutes."


Well, the FSM states that the A/T oil light will come on after the temp is raised above 150ºC (302ºF). The light goes off when the temperature falls below 120ºC (248ºF).

[concretejungle]

Originally Posted by jklubens

Got the following information from this web site HowStuffworks

Tech Tip Corner
Transmission Fluid


"Automatic Transmission Fluid Oxidation
Automatic transmission fluid will provide 100,000 miles of service before oxidation occurs under normal operating temperatures of about 170°F. Above normal operating temperatures, the oxidation rate doubles (useful life of fluid is cut in half) with each 20° increase in temperature.

The approximate life expectancy at various temperatures is as follows:


175°F 100,000 miles
195°F 50,000 miles
212°F 25,000 miles
235°F 12,000 miles
255°F 6,250 miles
275°F 3,000 miles
295°F 1,500 miles
315°F 750 miles
335°F 325 miles
355°F 160 miles
375°F 80 miles
390°F 40 miles
415°F Less than 30 minutes


This information clearly shows why transmission oil coolers and the various maintenance intervals are recommended for severe usage.

Above 300°F, the metals inside the transmission will warp and distort in varying degrees depending on the severity of overheat. Because this damage occurs and fluid life is so seriously impaired, rocking out of snow, mud or sand should never exceed a very few minutes."


Well, the FSM states that the A/T oil light will come on after the temp is raised above 150ºC (302ºF). The light goes off when the temperature falls below 120ºC (248ºF).

Hey, great post.

THanks,