FJ62 A440F Trans Rebuild

[Cruiser Jimmy]

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?

Spook,
I thought I'd reply to your questions after I went through the build and evaluate my SST's.

The OS was sourced from Dallen, great find because OEM is really expensive. However, I did find that Dacco Transmission Parts will rework OS's. I've got the old one but will not rework it right now. I'll have to find out the cost also. Dacco shows an illustrated parts breakdown in their catalog of most Toyota transmissions so one would assume that they get donor trannys in for parts.

There's not a lot of SST needed. The main ones that are really specific to trannys are the piston compressing tools and the arms for dial indicators. Everything else are tools that you might already have for inserting new seals or something like that.

There are four pistons in the tranny. Three are clutches and one is used for a brake. This one brake really requires the use of an SST because you need to compress spring and get a snap ring in place. I when to the hardware store with the dimensions of the piston spring hold ring (ring w/ the holes) and found that a 4" PVC cap is the same diameter as the spring ring. A threaded rod is needed and the black puck you see is the only SST that I bought. The SST puck is needed to drive the bearing into place at the bottom of the trans housing. I cut the cap to allow for access to put the snap ring in place. Here's the SST for this piston.




The three other pistons are the O/D piston and front and rear clutch assemblies.
Honestly, I used two c-clamps to compress the pistons in order to get the snap ring in place.

 

[Cruiser Jimmy]

Here are the dial indicator arms that I modded up. I used 1/8" rod with a 3mm X .5 pitch die for threading the rod.

 

[Cruiser Jimmy]

Could lock up be dependent on throttle position? I adjusted the slack out of my throttle cable and it seemed to mess up the lock up.
-curious.

The throttle cable runs to two pistons in the valve body (Primary and Secondary Throttle Valves) which are calibrated using shims. The hydraulic circuit require proper positioning to work as designed.

 

[redtoy]

so...how did this rebuild go? what were the results, all good?

 

[Randy88FJ62]

Skimmed the last page so I'm not sure if this point is still helpful. Georg at Valley Hybrids was gracious enough to let me borrow his McNamara Gear JIG. I had a spare gear and machined it down to just a spacer with splines. I then clamped it together with the gear assembly, pre-heated, welded, and post heated. The DIY McNamara Gear has not failed me yet.

Ironically I'll eventually have to sell it when I go to crawler gears in the tcase.

 

[Randy88FJ62]

Found the pics for reference:

First picture shows the gears clamped with the fixture and chamfers machined at the inner edges to provide more surface area for the weld. Second picture is after everything, ready for install.