FJ62 A440F Trans Rebuild

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Cruiser Jimmy

Cruiser Jimmy

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Fellas,
So I decided to undertake a transmission rebuild for a 62. The A440F is slightly different than an 80 A440F. The difference lies in the rear section of the transmission where it bolts to the transfer case. Not overly complicated, just different to which I won't go into detail about.

The donor trans has one big issue with it. The Output Shaft (OS) has 300K miles on it and the splines show it. Therefore it will need to be replaced as using the old one would just be stupid, unfair, unjust, and down right mean!! A result of using this OS which mean slop in the drive-line and an audible shatter sound when in park. The clutches and brake are burnt brown but still in good shaft. The steels are in even better shape and could be reused, it which I'll do. Since this trans had over 300K on the clock the Torque Converter will need to be looked at also. The main item of interest for a TC is the lockup plate given the milage. There is a clutch that's in it and just like the other clutches and brake it needs attention too.

There are a bunch of SST tools that I've made myself so measurements and assemble is going to be that much easier. Cleanliness is next to Godliness! A very clean environment for assemble is a must.

Here are some starter pics.

Teardown
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Here's the Output Shaft on this particular trans. Notice the material at what I judge to be 3/5 there. Really bad shape.
Clutches are brown'ed up but still has the ability to be used if needed due to the impending zombie apocalypse ransacking every building for food and parts not being able to be ordered. And by impending zombie apocalypse I mean the current proposed ban on weapons that the Democrats are pushing down Americans throats. Rant over!!
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Cruiser Jimmy said:
And by impending zombie apocalypse I mean the current proposed ban on weapons that the Democrats are pushing down Americans throats. Rant over!!
Click to expand...

Was interested in this thread until I read this. You might want to do a little research before making board statments.

Any new automatic weapons were banded from the public in 86. Which President was in office in 86? Then in 89 another band after a school shooting. http://en.wikipedia.org/wiki/Cleveland_School_massacre I voted for Bush sr. mainly because he promised no new gun laws. He wasn't even in office a year before his band. The driving force behind any band is out crys from the public after a tragedy like the one in Newtown. With the millions of guns already out there any band will not solve a thing. But argument one party is to blame for all the bands doesn't hold water. Rant over.:cheers:
 
Aaaaaaand steering this thread back on track....

Very cool to see a step by step on rebuilding an A440F, especially since I might end up keeping mine now. Interesting as well seeing just how much wear there is on the OS after 300K. That's about where I'm at and I was curious as to approximately how much mine had worn, wondering in fear just how long I had until the splines risk being sheared completely. Luckily it wasn't until fairly recently that I started getting the FJ62 clunk, so maybe mine isn't as bad as I had initially feared. Do you plan on sourcing a new OS, or just finding a donor that's not wearing nearly as much?

Also, what was your situation as far as SSTs needed? Is it a lot, or just a few that are required?

Sent from my Motorola DynaTAC 8000x
 
I too am eager to see you tackle this.
A McNamra Gear would solve the worn spline issue, but will do nothing for the 300k on the rest of your trans. Have fun!
 
Anyone remember who the Mudder was that did a very detailed, step by step, writeup of their A440F rebuild several years ago? As I recall, it lasted less than 10k miles. For whatever reasons, rebuilds of this tranny haven't been real successful. Best of luck to you, Cruiser Jimmy, we all hope yours is a success story. Looks like you have a good start.
 
overhanger said:
Anyone remember who the Mudder was that did a very detailed, step by step, writeup of their A440F rebuild several years ago? As I recall, it lasted less than 10k miles. For whatever reasons, rebuilds of this tranny haven't been real successful. Best of luck to you, Cruiser Jimmy, we all hope yours is a success story. Looks like you have a good start.
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You remember what it was that killed it?
 
The tranny that Cruiser Jimmy is rebuilding is out of my first cruiser. I got it from my dad who put on 200,000 miles then I put on the last 100,000. It had a rhythmic pulsing/vibration at highway speeds and when I opened it up I found that output shaft. I checked tonight and Toyota has the output shaft so I may be buying one soon. It will be interesting following the rebuild thread.
 
dallen341 said:
if I recall correct it was not replacing the torque converter.
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So did that ruin the rest of the tranny, or did he just have to pull it off again to install a new TC?
 
I remember reading (with interest) the thread in the 80's section. It was cruiser Jimmy who did the rebuild, and it was the torque converter that seemed to kill it. He should be in a great spot to guide us through this new rebuild. Jimmy you are an inspiration to me! Keep up the good work and please, keep us posted. You go where few have gone before!
 
Found the original thread: https://forum.ih8mud.com/80-series-tech/65907-tranny-rebuild-shadetree-mechanic-style.html

Reading through it right now. How in the hell did he get everything so clean???

Edit: Looks like it was the final assembly of the valve body that killed the torque converter, which in turn killed the rest of the tranny. Very interesting read. Makes me think that with a rebuilt valve body and TC from Rodney (along with a new output shaft and a McNamara gear for longevity of course), I might be able to attempt this myself if I keep the auto in my 62. At the very least we'll be keeping it for the short term, so at this point I'm just hoping it survives another couple years :D
 
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Spook50 said:
Do you plan on sourcing a new OS, or just finding a donor that's not wearing nearly as much?
Also, what was your situation as far as SSTs needed? Is it a lot, or just a few that are required?
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*A new driveshaft is in order. According to my local dealer there are five in the country.

*I bought one. A steel puck to drive a bearing into place. The rest I fab'ed up. A fork made to compress a spring to release a ball bearing, dial indicator arms so I could take measurements and off the shelf C-clamps to compress some springs to release keepers, etc. Not overly complected to fab.


Spook50 said:
So did that ruin the rest of the tranny, or did he just have to pull it off again to install a new TC?
Click to expand...

Spook50 said:
Reading through it right now. How in the hell did he get everything so clean???
Edit: Looks like it was the final assembly of the valve body that killed the torque converter, which in turn killed the rest of the tranny.
Click to expand...
The TC was not replaced. In fact, the entire assembly is still in my garage along with the TC. I consulted with several transmission shops around Indy and explained my entire situation without any leading details. From their remarks I determined that my valve body was not to blame. The condition that brought it down was while I was at highway speeds. I was heating up the trans because the lockup was slipping.
No other conditions presented itself than that. If the VB had an issue then that mean I would have had problems with driving in around town, in D; acceleration, deceleration, in R, in 3, in 2, in L. The first test in fact was I took it crawling at a local park and never had a problem.


Although this process is entertaining and a little voyeuristic on everyone's behalf the result of a good build and long term success is the end result.
 
dallen341 said:
I have an A440F trans from a 62 series that has pristine splines on it. Trans and/or shaft only available.
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If the shaft is out and you can take a picture of the splines just aft of were the seal is placed I would be interested to see but it's no guarantee that I'd request it for the build.
 
Cruiser Jimmy said:
The TC was not replaced. In fact, the entire assembly is still in my garage along with the TC. I consulted with several transmission shops around Indy and explained my entire situation without any leading details. From their remarks I determined that my valve body was not to blame. The condition that brought it down was while I was at highway speeds. I was heating up the trans because the lockup was slipping.
No other conditions presented itself than that. If the VB had an issue then that mean I would have had problems with driving in around town, in D; acceleration, deceleration, in R, in 3, in 2, in L. The first test in fact was I took it crawling at a local park and never had a problem.


Although this process is entertaining and a little voyeuristic on everyone's behalf the result of a good build and long term success is the end result.
Click to expand...

Interesting. I was under the impression that the VB wasn't sending enough pressure to the TC for a complete lockup, and that had been causing the slipping that killed it. I wonder if the original TC had been slipping at all before the rebuild. Looks like if I tackle something like this in the future, a new TC will be a must-have item.
 
Spook50 said:
Interesting. I was under the impression that the VB wasn't sending enough pressure to the TC for a complete lockup, and that had been causing the slipping that killed it. I wonder if the original TC had been slipping at all before the rebuild. Looks like if I tackle something like this in the future, a new TC will be a must-have item.
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Yeah, that was my impression too until I cut the TC open and took a look at the lockup. Showed it to some shops around Indy and they said the same thing.


I honestly think the lockup was slipping before my rebuild and before when I had it rebuilt. A line pressure check would also tell me definitively if there was a VB problem, but after doing a stall test, time lag test and driving test that's stated in the FSM and those checked out to be fine I did not do the line pressure test.
A refurbished TC is definitely a must for any new rebuild in my opinion. According to my vendor, to refurbish a TC is only $150. My vendor will take mine, send it to the DC and rework it and ship it back.
 
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