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Hybrid Vehicle Transaxle Unit: Disassembly

CAUTION:
  • When working on the high voltage systems, always wear insulated gloves.
  • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle.
  • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes.
NOTE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU.
  1. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY 
    1. Remove the hybrid vehicle transaxle (see REMOVAL  ).
  2. REMOVE HYBRID VEHICLE GENERATOR ASSEMBLY 
    1. Install the 2 engine hangers in the positions shown in the illustration.

      HINT:

      • Engine hanger: 12281-67070, S1228-11781
      • Bolt: 91642-81045, 91642-81265
      • Nut: 90178-10001, 90179-12147
    2. Using an engine sling device and chain block, set the transaxle with the generator side facing upward.
      NOTE:
      • Place the transaxle on wooden blocks or equivalent.
      • Fix the transaxle so that no excessive force is applied to the cable.
    3. Remove the drain plug.
      Fig 1: Installing Engine Hangers
      G04474139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 21 bolts shown in the illustration.

      HINT:

      • 13 bolts on the generator side.
      • 8 bolts on the motor side.
        Fig 2: Removing Hybrid Vehicle Generator Assembly Bolts
        G04474140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the motor and generator by inserting a flat-head screwdriver in the position shown and prying the two apart.
      NOTE: Be careful not to damage the two faces of each part.
    6. Using an engine sling device and chain block, raise the generator.

      HINT:

      Raise the generator approximately 30 to 40 mm (1.18 to 1.57 in.).

      Fig 3: Inserting Screwdriver Between Hybrid Vehicle Generator Assembly Body
      G04474141Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Apply protective tape to the head of a flat-head screwdriver and use it to hold down the chain with input shaft while removing the generator.
      Fig 4: Holding Down Chain With Input Shaft While Removing Generator Using Screwdriver
      G04474142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE COUNTER DRIVEN GEAR SUB-ASSEMBLY 
    1. Remove the counter driven gear from the HV motor.
      Fig 5: Removing Counter Driven Gear From HV Motor
      G04474143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE DIFFERENTIAL CASE ASSEMBLY 
    1. Remove the differential case from the HV motor.
      Fig 6: Removing Differential Case From HV Motor
      G04474144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE TRANSMISSION DRIVE SPROCKET SUB-ASSEMBLY 
    1. Remove the thrust bearing race, thrust needle roller bearing and No. 1 thrust bearing race.

      HINT:

      The thrust bearing race may be attached to the generator side.

      Fig 7: Removing Thrust Bearing Race And Thrust Needle Roller Bearing
      G04474145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the drive sprocket and chain.
      Fig 8: Removing Drive Sprocket And Chain
      G04474146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE INPUT SHAFT ASSEMBLY 
    1. Remove the input shaft.
      Fig 9: Removing Input Shaft
      G04474147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE PLANETARY RING GEAR 
    1. Remove the thrust bearing race, thrust needle roller bearing and No. 1 thrust bearing race.

      HINT:

      The thrust bearing race may be attached to the input shaft side.

      Fig 10: Removing Thrust Bearing Race And Thrust Needle Roller Bearing
      G04474148Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the planetary ring rear.
      Fig 11: Removing Planetary Ring Rear
      G04474149Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE PLANETARY RING GEAR FLANGE 
    1. Remove the planetary ring gear flange and shim.
      Fig 12: Removing Planetary Ring Gear Flange And Shim
      G04474150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE SPROCKET DRIVEN GEAR AND COUNTER DRIVE GEAR 
    1. Using a plastic-faced hammer, tap the motor case and remove the counter drive gear and shim.

      HINT:

      Remove the counter drive gear while pulling it vertically.

      Fig 13: Removing Counter Drive Gear And Shim Using Hammer
      G04474151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. FIX TRANSMISSION OIL STRAINER 
    1. Remove the bolt and oil strainer.
      Fig 14: Removing Oil Strainer Bolt
      G04474152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring from the oil strainer.
      Fig 15: Removing O-Ring From Oil Strainer
      G04474153Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE HV MOTOR ASSEMBLY 
    1. Place the motor on wooden blocks or equivalent.
      Fig 16: Placing Motor On Wooden Blocks
      G04474154Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE NO. 3 ENGINE MOUNTING BRACKET 
    1. Remove the 3 bolts and mounting bracket.
      Fig 17: Removing Engine Mounting Bracket
      G04474155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE MOTOR REVOLUTION SENSOR WIRING HARNESS CONNECTOR 
    1. Remove the bolt and pull out the HV motor side motor revolution sensor wiring harness connector (gray).
      NOTE: Do not pull on the connector any more than necessary.
    2. Remove the connector and motor revolution sensor wiring harness connector (gray).
      Fig 18: Removing Motor Revolution Sensor Wiring Harness Connector
      G04474156Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE MOTOR STATOR WIRING HARNESS CONNECTOR 
    1. Remove the bolt and pull out the motor stator wiring harness connector (black).
      NOTE: Do not pull on the sensor connector any more than necessary.
    2. Disconnect the connector and the motor stator wiring harness connector (black).
      Fig 19: Removing Motor Stator Wiring Harness Connector
      G04474157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE SHIFT CONTROL ACTUATOR ASSEMBLY 
    1. Remove the 3 bolts and shift control actuator.
      Fig 20: Removing Shift Control Actuator
      G04474158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE PARKING COVER 
    1. Remove the 6 bolts and parking cover.
      Fig 21: Removing Parking Cover
      G04474159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY 
    1. Remove the bolt, manual detent spring cover and manual detent spring.
      Fig 22: Removing Manual Detent Spring Cover And Manual Detent Spring
      G04474160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE MOTOR WATER JACKET COVER 
    1. Remove the 6 bolts and motor water jacket cover.
      Fig 23: Removing Motor Water Jacket Cover
      G04474161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE PARKING SHAFT COVER 
    1. Remove the 5 bolts and parking shaft cover.
      Fig 24: Removing Parking Shaft Cover
      G04474162Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE TRANSMISSION OIL PUMP COVER SUB-ASSEMBLY 
    1. Remove the oil pump cover plug and O-ring.
      Fig 25: Removing Oil Pump Cover Plug And O-Ring
      G04474163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 bolts and oil pump cover.
      Fig 26: Removing Oil Pump Cover
      G04474164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the O-ring.
      Fig 27: Identifying Transmission Oil Pump Cover Sub-Assembly O-Ring
      G04474165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE OIL PUMP DRIVE SHAFT 
    1. Remove the oil pump drive rotor and oil pump driven rotor.
      Fig 28: Removing Oil Pump Drive Rotor And Oil Pump Driven Rotor
      G04474166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the oil pump drive shaft.
      Fig 29: Removing Oil Pump Drive Shaft
      G04474167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE DIFFERENTIAL CASE LH TAPERED ROLLER BEARING RACE 
    1. Using SST, tap out the differential case tapered roller bearing LH outer race and shim.

      SST 09308-00010 

      Fig 30: Removing Differential Case LH Tapered Roller Bearing Race
      G04474168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE HYBRID TRANSAXLE OIL SEAL LH 
    1. Place the motor on wooden blocks or equivalent.
      NOTE: Make sure that the parking lock rod does not contact the wooden blocks.
      Fig 31: Placing Motor On Wooden Blocks
      G04474169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, tap out the oil seal.

      SST 09308-00010 

      Fig 32: Removing Hybrid Transaxle Oil Seal LH
      G04474170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE TRANSAXLE HOUSING AND CASE WITH HEAD STRAIGHT SCREW PLUG 
    1. Remove the 2 set plugs and gasket.
    2. Using a 10 mm hexagon wrench, remove the screw plugs.
      Fig 33: Removing Screw Plugs And Set Plugs
      G04474171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. FIX HYBRID VEHICLE GENERATOR ASSEMBLY 
    1. Place the generator on wooden blocks or equivalent.
      Fig 34: Placing Generator On Wooden Blocks
      G04474172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE POWER CABLE COVER 
    1. Remove the breather plug.
      Fig 35: Removing Breather Plug
      G04474173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 bolts and power cable cover.
      Fig 36: Removing Power Cable Cover
      G04474174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE GENERATOR CABLE 
    1. Remove the 5 bolts and generator cable.
      Fig 37: Removing Generator Cable
      G04474175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE GENERATOR MOTOR REVOLUTION SENSOR WIRING HARNESS CONNECTOR 
    1. Remove the bolt and pull out the HV generator side generator revolution sensor wiring harness connector.
      NOTE: Do not pull on the sensor connector any more than necessary.
    2. Disconnect the connector and the HV generator side generator revolution sensor wiring harness connector.
      Fig 38: Removing Generator Motor Revolution Sensor Wiring Harness Connector
      G04474176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE TRANSAXLE HOUSING TUBE CONNECTOR 
    Fig 39: Removing Transaxle Housing Tube Connector
    G04474177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY TYPE T OIL SEAL 
    1. Using SST, remove the oil seal.

      SST 09612-30012 

      Fig 40: Removing Hybrid Vehicle Transaxle Assembly Type T Oil Seal
      G04474178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE HYBRID TRANSAXLE OIL SEAL RH 
    1. Using SST, tap out the oil seal.

      SST 09308-00010 

      Fig 41: Removing Hybrid Transaxle Oil Seal RH
      G04474179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE DIFFERENTIAL CASE RH TAPERED ROLLER BEARING RACE 
    1. Using SST, tap out the differential case tapered roller bearing LH outer race.

      SST 09308-00010 

      Fig 42: Removing Differential Case Tapered Roller Bearing LH Outer Race
      G04474180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE TRANSAXLE HOUSING AND CASE WITH HEAD STRAIGHT SCREW PLUG 
    1. Remove the set plug and gasket.
    2. Using a 6 mm socket wrench, remove the screw plug.
      Fig 43: Removing Screw Plug And Set Plug
      G04474181Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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