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HV Battery: Disassembly

  1. INSTALL ENGINE HUNGER 

    Install the engine hanger onto the MG1 side as shown in Fig 1, and lift it up by a chain device.

    Engine hanger part No.: 12281-67070, S1228-11781 

    Bolt part No.: 91642-81045 91642-81265 2 pieces 

    Nut part No.: 90178-10001 90179-12147 2 pieces 

    Fig 1: Installing Engine Hunger
    G03452741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • As the transaxle itself is heavy, place a wood block underneath to stabilize it and carry out the operation carefully. 
    • Do not pull or bend the high-voltage cable of the MG1 assembly. 
    • Drain the fluid before disassembly. 
  2. REMOVE MG1 ASSEMBLY 
    1. Remove the 21 bolts.
      Fig 2: Removing MG1 Assembly Bolts
      G03452742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver and a hammer, disconnect the MG1 assembly from the MG2 assembly.
      Fig 3: Disconnecting MG1 Assembly From MG2 Assembly
      G03452743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: When separating the MG1 assembly from the MG2 assembly, to prevent the drive sprocket from being removed with the MG1 assembly, push down the chain part with a taped screwdriver tip.
    Fig 4: Precautions For Separating MG1 Assembly From MG2 Assembly
    G03452744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE COUNTER DRIVEN GEAR ASSEMBLY 

    Remove the counter driven gear assembly from the MG2 assembly.

    Fig 5: Removing Counter Driven Gear Assembly From MG2 Assembly
    G03452745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE DIFFERENTIAL CASE ASSEMBLY 

    Remove the differential case assembly from the MG2 assembly.

    Fig 6: Removing Differential Case Assembly From MG2 Assembly
    G03452746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE 2 RACES AND NEEDLE ROLLER BEARING 
    Fig 7: Removing Races And Needle Roller Bearing
    G03452747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE DRIVE SPROCKET SUB-ASSEMBLY AND CHAIN 
    Fig 8: Removing Drive Sprocket Sub-Assembly And Chain
    G03452748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE INPUT SHAFT ASSEMBLY 
    1. Remove the input shaft assembly.
      Fig 9: Removing Input Shaft Assembly
      G03452749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the needle roller bearing and 2 bearing races.
      Fig 10: Removing Needle Roller Bearing And Bearing Races
      G03452750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE PLANETARY RING GEAR 
    Fig 11: Removing Planetary Ring Gear
    G03452751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE RING GEAR FLANGE AND SHIM 
    Fig 12: Removing Ring Gear Flange And Shim
    G03452752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE COUNTER DRIVE GEAR AND SHIM 
    NOTE: Remove the counter drive gear by tapping the case with a plastic hammer.
    Fig 13: Removing Counter Drive Gear And Shim
    G03452753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE OIL PAN AND GASKET 
    1. Remove the drain plug and its gasket.
    2. Remove the 12 bolts.
    3. Remove the oil pan and its gasket.
      Fig 14: Removing Oil Pan And Gasket
      G03452754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE MAGNET FROM OIL PAN 
    Fig 15: Removing Magnet From Oil Pan
    G03452755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. EXHAUST PARTICLES IN PAN 

    Remove the magnet and use it to collect any steel chips. Carefully examine the chips and particles in the oil pan and on the magnet to identify what type of wear has occurred in the transaxle.

    Fig 16: Identifying Exhaust Particles In Pan
    G03452756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Steel (magnetic): bearing, gear and plate wear
    • Brass (non-magnetic): bushing wear
  14. REMOVE OIL STRAINER 
    1. Remove the bolt and oil strainer.
      Fig 17: Removing Oil Strainer
      G03452757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring from the oil strainer.
      Fig 18: Removing O-Ring From Oil Strainer
      G03452758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. SET MG2 ASSEMBLY 

    As illustrated, set the MG2 assembly and wood blocks.

    Fig 19: Assembling MG2 Assembly And Wood Blocks
    G03452759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE MOUNTING BRACKET 

    Remove the 3 bolts and mounting bracket.

    Fig 20: Removing Bolts And Mounting Bracket
    G03452760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE WIRING HARNESS CONNECTOR (MG2 side) 

    Remove the 2 bolts and the 2 wiring harness connectors.

    Fig 21: Removing Wiring Harness Connectors (MG2 Side)
    G03452761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE 2 WATER JACKET UNIONS (MG2 side) 
    Fig 22: Removing Water Jacket Unions (MG2 Side)
    G03452762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE PARKING COVER 

    Remove the 6 bolts and parking cover.

    Fig 23: Removing Bolts And Parking Cover
    G03452763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE DETENT SPRING COVER AND DETENT SPRING 

    Remove the bolt, detent spring cover and detent spring.

    Fig 24: Removing Bolt, Detent Spring Cover And Detent Spring
    G03452764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE MOTOR WATER JACKET COVER 

    Remove the 6 bolts and motor water jacket cover.

    Fig 25: Removing Bolts And Motor Water Jacket Cover
    G03452765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE PARKING SHAFT COVER 
    1. Remove the 5 bolts and parking shaft cover.
      Fig 26: Removing Bolts And Parking Shaft Cover
      G03452766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, remove the oil seal from the cover.
      Fig 27: Removing Oil Seal From Cover
      G03452767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE PARKING LOCK SHAFT ASSEMBLY 
    Fig 28: Removing Parking Lock Shaft Assembly
    G03452768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. DISASSEMBLE PARKING LOCK SHAFT ASSEMBLY 
    1. Remove the washer.
      Fig 29: Removing Washer
      G03452769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a chisel and a hammer, cut the spacer.
      3. Fig 30: Removing Spacer
      G03452770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the spacer.
    4. Using a pin punch and a hammer, drive out the pin.
      5. Fig 31: Removing Parking Lock Lever No. 3 From Parking Lock Shaft
      G03452771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the parking lock lever No. 3 from the parking lock shaft.
  25. REMOVE OIL PUMP 
    1. Remove the plug.
    2. Remove the O-ring from the plug.
      Fig 32: Removing O-Ring From Plug
      G03452772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 5 bolts and oil pump cover.
      Fig 33: Removing Oil Pump Cover
      G03452773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the O-ring.
      Fig 34: Removing O-Ring
      G03452774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the oil pump driven rotor and drive rotor.
      Fig 35: Removing Oil Pump Driven Rotor And Drive Rotor
      G03452775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the oil pump drive shaft.
      Fig 36: Removing Oil Pump Drive Shaft
      G03452776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE DIFFERENTIAL SIDE BEARING OUTER RACE LH AND SHIM (MG2 SIDE) 

    Using SST, drive out the differential side bearing outer race and shim.

    Fig 37: Removing Differential Side Bearing Outer Race And Shim
    G03452777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    SST 09308-00010

  27. REMOVE COUNTER DRIVEN GEAR SIDE BEARING OUTER RACE LH AND SHIM 
    1. Using SST, drive out the counter driven gear side bearing outer race and shim.

      SST 09308-00010

      Fig 38: Removing Counter Driven Gear Side Bearing Outer Race And Shim
      G03452778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Overturn the MG2 assembly and place a wood block under it stabilize
      Fig 39: Placing MG2 Assembly On Wood Block
      G03452779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      CAUTION: Be careful not to bend the parking lock rod.
  28. REMOVE DIFFERENTIAL OIL SEAL LH (MG2 side) 

    Using a screwdriver, drive out the oil seal.

    Fig 40: Removing Oil Seal
    G03452780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE FILLER PLUG AND SCREW PLUG (MG2 side) 
    1. Remove the 2 screw plugs with a hexagon wrench.
      2. Fig 41: Removing Filler Plugs And Gaskets
      G03452781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 filler plugs and the 2 gaskets.
  30. REMOVE BREATHER PLUG 
    Fig 42: Removing Breather Plug
    G03452782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. PLACE WOOD BLOCK UNDER MG1 ASSEMBLY TO STABILIZE 
    Fig 43: Placing Wood Block Under MG1 Assembly
    G03452783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE HIGH-VOLTAGE CABLE 
    1. Remove the 4 bolts and power cable cover.
      Fig 44: Removing Bolts And Power Cable Cover
      G03452784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 6 bolts and the high-voltage cable.
      Fig 45: Removing High-Voltage Cable
      G03452785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE WIRING HARNESS CONNECTOR (MG1 SIDE) 

    Remove the bolt and wiring harness connector.

    Fig 46: Removing Wiring Harness Connector (MG1 Side)
    G03452786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE 2 WATER JACKET UNIONS (MG1 SIDE) 
    Fig 47: Removing Water Jacket Unions (MG1 Side)
    G03452787Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE HOUSING TUBE 
    Fig 48: Removing Housing Tube
    G03452788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE INPUT SHAFT OIL SEAL 

    Using SST, drive out the input shaft oil seal. SST 09612-30012

    Fig 49: Removing Input Shaft Oil Seal
    G03452789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE DIFFERENTIAL OIL SEAL RH (MG1 SIDE) 

    Using a screwdriver, drive out the differential oil seal RH.

    Fig 50: Removing Differential Oil Seal RH (MG1 Side)
    G03452790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. TURN MG1 ASSEMBLY UPSIDE DOWN 
  39. REMOVE PARKING LOCK PAWL 
    1. Remove the bolt and the lock clamp.
      Fig 51: Removing Bolt And Lock Clamp
      G03452791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the parking lock pawl shaft.
      3. Fig 52: Removing Parking Lock Pawl Shaft
      G03452792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the parking lock pawl.
  40. REMOVE PARKING LOCK SLEEVE 
    1. Remove the 2 bolts, sleeve bracket, torsion spring and parking lock sleeve.
      Fig 53: Removing Sleeve Bracket, Torsion Spring And Parking Lock Sleeve
      G03452793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the cam guide sleeve from the sleeve bracket.
      Fig 54: Removing Cam Guide Sleeve From Sleeve Bracket
      G03452794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE COUNTER DRIVEN GEAR SIDE BEARING OUTER RACE RH (MG1 SIDE) 

    Using SST, drive out the counter driven gear side bearing outer race RH. SST 09308-00010

    Fig 55: Removing Counter Driven Gear Side Bearing Outer Race RH
    G03452795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE DIFFERENTIAL SIDE BEARING OUTER RACE RH (MG1 SIDE) 

    Using SST, drive out the differential side bearing outer race RH. SST 09308-00010

    Fig 56: Removing Differential Side Bearing Outer Race RH
    G03452796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE DRAIN PLUG AND SCREW PLUG (MG1 SIDE) 
    1. Remove the screw plug from the MG1 assembly with a hexagon wrench.
      2. Fig 57: Removing Drain Plug And Gasket
      G03452797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the drain plug and the gasket.
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