Don't like the adverts?  Click here to remove them

A442F valve body gasket replacement / service

Jon Wildsmith

Super Moderator
Supporter
Guru
Joined
Feb 24, 2010
Messages
6,753
Garage
Country Flag
england
When removing the valve body from an A442F that has been in situ for a long time there's a pretty good chance you won't get the valve body out with the gasket intact because it sticks to the gearbox. Even if you're very very careful it can still end up tearing. I'm working my way through a rebuild of Ray's dead A442F gearbox and thought I'd document splitting the valve body to replace the gaskets. It was also a good chance to check that there was no debris from when the clutch plates disintegrated hiding in there.

This is the top side of the valve body that mates with the gearbox. The green arrow shows a pipe that covers one of the bolts you'll be needing to remove. Just remove the plate you see covering part of the pipe and then gently lever the pipe out. I also have a valve body here that has that pipe longer and bent around the bolt so it can still be removed with the pipe in place.

Image0274.jpg


This is the underside of the valve body and is what you see if you take the oil pan off:

Image0278.jpg


Remove the 8mm headed bolts till it looks like this (not all bolts are removed):

Image0281.jpg


Then turn it over and remove 8mm headed bolts till it looks like this:

Image0282.jpg


Now you need to be careful if you don't want to make this much harder than it needs to be! Between the two main parts of the valve body is a metal plate with a gasket each side. With the valve body orientated as in the above picture, lift the metal plate up with the upper valve body on it. The plate will stop the loose parts of the upper valve body falling out. Then carefuly hold the plate against the valve body while you flip it over and put it down.

This is the inside of the lower valve body which has a couple of loose parts to fall out:

Image0283.jpg


This is the upper valve body flipped with the plate still on top and the old gasket removed.

Image0285.jpg


This is inside the upper valve body which has lots of little ball bearings waiting to fall out if you're not careful:

Image0286.jpg


All together:

Image0287.jpg


Then you just clean up the parts, pop the new gaskets on and put it all back together. You have to be careful when lining up the plate and two gaskets not to lose anything. There are several different lengths of bolts used. The gearbox FSM does document the lengths if you get stuck but I just put them down in the order they came out and then reversed that to put them back.

Next installment for the A442F threads should be rebuilding the main part of the gearbox.
 

Attachments

  • Image0274.jpg
    Image0274.jpg
    150.8 KB · Views: 261
  • Image0278.jpg
    Image0278.jpg
    157.6 KB · Views: 257
  • Image0281.jpg
    Image0281.jpg
    153.9 KB · Views: 268
  • Image0282.jpg
    Image0282.jpg
    167.2 KB · Views: 336
  • Image0283.jpg
    Image0283.jpg
    212.8 KB · Views: 269
  • Image0285.jpg
    Image0285.jpg
    154.9 KB · Views: 274
  • Image0286.jpg
    Image0286.jpg
    192.1 KB · Views: 273
  • Image0287.jpg
    Image0287.jpg
    144.6 KB · Views: 282

Chris

Super Moderator
Supporter
Joined
Feb 24, 2010
Messages
17,456
Garage
Country Flag
europe
Jon, may I ask just what symptom does this cure. You say that this is a dead auto box. What actually happened and do you know why? It looks somewhat scary but with your usual confidence make it sound very straightforward. Hopefully none of ours will ever fail, but faced with a huge cost for a replacement of unknown condition, is this a typically common fault that we could repair? Obviously there are all sorts of moving bits too which are not covered in this thread. Will you be taking all the other section apart for surgery too?

Chris
 

Jon Wildsmith

Super Moderator
Supporter
Guru
Joined
Feb 24, 2010
Messages
6,753
Garage
Country Flag
england
Until I take the main part of the gearbox apart I won't know for sure what went wrong but the pieces of clutch material floating about suggest sudden clutch friction plate failure. Symptoms were the truck would be able to drive a short distance and then lose drive and it was making a nasty noise even on tick over. It could be that the oil pump failed and that the clutches were a secondary failure. I just thought I'd open it up and see if I could rebuild it or at least take lots of pictures to show what's in there :D Taking the valve body off is part of that process and the gasket was cooked onto the gearbox so had to be changed. That gasket doesn't normaly fail unless you have to remove the valve body. I just thought it would be interesting to see if an auto box rebuild is really a specialist job worth so much money or is really a bit of a rip off.

There's a broken manual gearbox waiting for me to have a look inside and make lots of scrap parts from as well :lol:
 

BobMurphy

Well-Known Member
Joined
Mar 1, 2010
Messages
1,650
Country Flag
scotland
JEEEEEEEEEZZZE :o

You have to admire whoever thought that up - or programmed the computer that designed it.

That's the sort of job that would keep me awake at night - until I'd done it (successfully) a couple of times.

Good effort (bet you're glad you're not relying on it to get you to work in the morning) :clap: .

Bob.
 

Jon Wildsmith

Super Moderator
Supporter
Guru
Joined
Feb 24, 2010
Messages
6,753
Garage
Country Flag
england
I wish I had the time to study it properly and work out what all of it does and how it might be tweaked like Wholesale Automatics do. I just thought people might like to see a bit more of the insides of an automatic gearbox and see if we can get a bit of insight into how they work and how they break.
 

Chas

Well-Known Member
Supporter
Joined
Mar 15, 2010
Messages
17,373
Garage
Country Flag
england
Jon Wildsmith said:
I just thought people might like to see a bit more of the insides of an automatic gearbox.
And now I've seen it :shock: I hope mine never goes wrong, it looks like something out of the TARDIS :lol:
Chas
 
Don't like the adverts?  Click here to remove them

pugwash

Well-Known Member
Joined
Mar 1, 2010
Messages
389
Country Flag
uk
this has just saved my life- thanks John

I've got the valve body on the bench ready to strip down and replace the torn gaskets (there's 2 right? one either sidfe of the plate?) and thought i'd pop in and see if the valve body has any small parts that need to be cared for.

am hoping that the throttle cable replacement that i've done will have cured the slightly odd problems i've been having, otherwise i'll be stripping the box down and hoping that it isn't too shagged!
 

Jon Wildsmith

Super Moderator
Supporter
Guru
Joined
Feb 24, 2010
Messages
6,753
Garage
Country Flag
england
Yes Jim, 2 gaskets, one either side of the metal plate. I can't remember how much they were exactly but pretty sure £15 isn't too far off the mark from a Toyota dealer. Good luck :)
 

nivapilot

Well-Known Member
Joined
Apr 6, 2011
Messages
428
Country Flag
england
Yea gods will you take a look inside that little box of tricks........think I might take it a bit easier with the auto box now.. :o
 

Andy

Well-Known Member
Supporter
Joined
Mar 7, 2010
Messages
773
Country Flag
england
Excellent, as always, Jon

I'll be watching this thread with interest, as I also wondered why they were so 'specialist' when it comes to repairs, not that I want to be at the stage where I've got to find out!!!
Andy
 

pugwash

Well-Known Member
Joined
Mar 1, 2010
Messages
389
Country Flag
uk
perhpas i should note that this was the 2nd or 3d seacrh result for A442f valve body on google!

dont' know why i didn't just search here first :clap: :clap:

John- do you happen to have a partnumber for the 4 littel round gaskets that sit above the valvebdoy- called something like a "support gasket"

can't find them in either the FSM or on the EPC :(
 

Jon Wildsmith

Super Moderator
Supporter
Guru
Joined
Feb 24, 2010
Messages
6,753
Garage
Country Flag
england
pugwash said:
John- do you happen to have a partnumber for the 4 littel round gaskets that sit above the valvebdoy- called something like a "support gasket"
35893-36010 are what you're after, in the EPC as 'gasket, center support apply' but not very obvious in the EPC unless you know.
 
Top