Tranny Rebuild -Shadetree Mechanic Style

Cruiser Jimmy · 11-02-05, 08:37 PM

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 · 11-02-05, 08:40 PM

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 · 11-02-05, 08:45 PM

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 · 11-02-05, 08:50 PM

Quote:

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 · 11-02-05, 08:52 PM

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 · 11-02-05, 08:57 PM

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 · 11-02-05, 09:01 PM

Quote:

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 · 11-02-05, 09:01 PM

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

Rich · 11-02-05, 09:07 PM

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

Cruiser Jimmy · 11-02-05, 09:10 PM

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 · 11-02-05, 09:14 PM

Quote:

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 · 11-02-05, 09:31 PM

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

cruiserdan · 11-02-05, 09:34 PM

Regretably the SST's he inquired about are discontinued.

Cruiser Jimmy · 11-02-05, 09:39 PM

Quote:

Originally Posted by cruiserdan

Regretably the SST's he inquired about are discontinued.

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

Cruiser Jimmy · 11-02-05, 09:53 PM

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 · 11-02-05, 10:08 PM

Awesome. Simply awesome.

DougM

absurdum80 · 11-02-05, 10:40 PM

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 · 11-02-05, 10:52 PM

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

cruiserdan · 11-02-05, 11:53 PM

Quote:

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 · 11-02-05, 11:54 PM

Quote:

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 · 11-03-05, 03:52 AM

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 · 11-03-05, 04:36 AM

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 · 11-03-05, 06:26 AM

Quote:

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 · 11-03-05, 06:30 AM

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 · 11-03-05, 06:35 AM

Quote:

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 · 11-03-05, 07:52 AM

Quote:

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 · 11-03-05, 11:42 AM

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 · 11-03-05, 01:21 PM

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

11-02-05, 08:37 PM	#1
Cruiser Jimmy IH8MUD Lifer Join Date: Sep 2004 Location: Indy,IN TLCA# 12112 Posts: 1,246	Tranny Rebuild -Shadetree Mechanic Style 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. Attached Images __________________ TLCA Chapter Club '92 FJ80, '83,'87 FJ60 2008 Toyota Trail Teams: East Coast Last edited by Cruiser Jimmy; 01-08-06 at 09:23 AM.

11-02-05, 08:40 PM	#2
Cruiser Jimmy IH8MUD Lifer Join Date: Sep 2004 Location: Indy,IN TLCA# 12112 Posts: 1,246	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. Attached Images __________________ TLCA Chapter Club '92 FJ80, '83,'87 FJ60 2008 Toyota Trail Teams: East Coast Last edited by Cruiser Jimmy; 01-08-06 at 09:22 AM.

11-02-05, 08:45 PM	#3
peebles24 IH8MUD Regular Join Date: May 2005 Location: Terre Haute, IN TLCA# 15403 Posts: 359	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 __________________ 1991 FJ80 mostly stock, for NOW. First ever Toyota 1976 FJ40 with a bunch of stuff done. SOLD you will be missed. check out my ROTW http://forum.ih8mud.com/showthread.php?t=84748 Second Toyota and I'm sure there will be more. www.hoosiercruiser.org Check out a web site I put together about my trucks and the Hoosier Cruisers http://www.cardomain.com/ride/2113715 or you can visit me on myspace http://www.myspace.com/cruiserpeebles

11-02-05, 08:52 PM	#5
landtank ThinkTank Waterboy Join Date: Mar 2003 Location: Boston MA Posts: 11,120	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? __________________ Rick Bigelow '96 215k Groveland MA 01834 If you're not the lead dog, the view never changes

11-02-05, 08:57 PM	#6
Cruiser Jimmy IH8MUD Lifer Join Date: Sep 2004 Location: Indy,IN TLCA# 12112 Posts: 1,246	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. Attached Images __________________ TLCA Chapter Club '92 FJ80, '83,'87 FJ60 2008 Toyota Trail Teams: East Coast Last edited by Cruiser Jimmy; 12-29-05 at 05:48 AM.

11-02-05, 09:01 PM	#8
Benji IH8MUD Lifer Join Date: Feb 2004 Location: Bloomington IN TLCA# 14119 Posts: 1,010	One brave man, good luck. If you need help, give me a hollar. __________________ Hoosier Cruisers http://www.hoosiercruiser.org/ 84 FJ60 - TLCA # 14119

11-02-05, 09:07 PM	#9
Rich IH8MUD Lifer Join Date: Jun 2003 Posts: 1,794	http://toyota.spx.com is where to get the toyota special tools.

11-02-05, 09:10 PM	#10
Cruiser Jimmy IH8MUD Lifer Join Date: Sep 2004 Location: Indy,IN TLCA# 12112 Posts: 1,246	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 Attached Images __________________ TLCA Chapter Club '92 FJ80, '83,'87 FJ60 2008 Toyota Trail Teams: East Coast

11-02-05, 09:31 PM	#12
Cruiser Jimmy IH8MUD Lifer Join Date: Sep 2004 Location: Indy,IN TLCA# 12112 Posts: 1,246	Here's a shot of a steel plate. It must be replaced. Attached Images __________________ TLCA Chapter Club '92 FJ80, '83,'87 FJ60 2008 Toyota Trail Teams: East Coast Last edited by Cruiser Jimmy; 11-30-05 at 10:17 PM.

11-02-05, 09:34 PM	#13
cruiserdan Parts Shaman (per Romer) Join Date: Mar 2003 Location: Where's my glasses? TLCA# 11332 Posts: 14,053	Regretably the SST's he inquired about are discontinued. __________________ Original owner 93 FZJ80,locked,blown,water/methanol injected(like a WWII fighter aircraft),lifted,winched,snorkeled,slidered,Sleeed ,moneypit. Balanced on a pin head. 95 FZJ80 trail truck (hers), 94 FZJ80 320K with a knock and a lumpy old Dodge car.

11-02-05, 09:53 PM	#15
Cruiser Jimmy IH8MUD Lifer Join Date: Sep 2004 Location: Indy,IN TLCA# 12112 Posts: 1,246	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. Attached Images __________________ TLCA Chapter Club '92 FJ80, '83,'87 FJ60 2008 Toyota Trail Teams: East Coast Last edited by Cruiser Jimmy; 12-29-05 at 05:52 AM.

11-02-05, 10:08 PM	#16
IdahoDoug IH8MUD Lifer Join Date: Aug 2003 Posts: 6,548	Awesome. Simply awesome. DougM __________________ Buy Head Gasket DVD for you OR for your mechanic HERE '93 FZJ since new, 2.2kw starter, Revo 275s, locked, big Hellas, rr fog, rr flood, rr Airlift, synthetics, ARB bullbar. 97 FZJ - exact same stuff but Michelin Alpins in winter "Slicker than owl shit on a wet log." - Carter

11-02-05, 10:40 PM	#17
absurdum80 IH8MUD Rookie Join Date: Aug 2005 Location: NE,GA TLCA# 14347 Posts: 1	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.

11-02-05, 10:52 PM	#18
baxter650 IH8MUD Regular Join Date: Aug 2005 Location: Abbotsford B.C. Posts: 469	3 years on a rebuild, i hope you at least gave them a call to tell them they suck at rebuilding. __________________ 1980 PU 9" lift 383 38" Swampers 1993 FZJ80 6" slee lift 37s 2000 XR671L 83 BJ60 under construction 2008 XR650L

11-03-05, 03:52 AM	#21
beno IH8MUD Lifer Join Date: Aug 2004 Location: Corrales, NM TLCA# 14607 Posts: 3,806	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 __________________ 1997 FZJ80 with and without lots of stuff. 2001 Honda Accord 3.0L V6 VTEC Coupe EX. It is what it is....

11-03-05, 04:36 AM	#22
cruiser larry IH8MUD Regular Join Date: Feb 2005 Location: Indiana TLCA# 14109 Posts: 364	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.

11-03-05, 06:30 AM	#24
Cruiser Jimmy IH8MUD Lifer Join Date: Sep 2004 Location: Indy,IN TLCA# 12112 Posts: 1,246	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. __________________ TLCA Chapter Club '92 FJ80, '83,'87 FJ60 2008 Toyota Trail Teams: East Coast

11-03-05, 11:42 AM	#27
Cruiser Jimmy IH8MUD Lifer Join Date: Sep 2004 Location: Indy,IN TLCA# 12112 Posts: 1,246	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 __________________ TLCA Chapter Club '92 FJ80, '83,'87 FJ60 2008 Toyota Trail Teams: East Coast Last edited by Cruiser Jimmy; 11-06-05 at 10:54 PM.