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Hybrid Transaxle Assembly: Disassembly

    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.
    Fig 1: Mounting Engine Hanger
    G01065930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Install the engine hanger onto the MG1 side as shown in Fig 1, and lift it up by a chain device.
    1. Engine hanger part No.  12281-67070, S1228-11781.
    2. Bolt part No.  91642-81045, 91642-81265 2 pieces.
    3. Nut part No.  90178-10001, 90179-12147 2 pieces.
  2. Remove MG1 assembly  :
    1. Remove the 21 bolts.
      Fig 2: Locating Motor Generator No. 1 Assembly Bolts
      G01065931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. CAUTION: 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 3: Pushing Down On Chain With Screwdriver Tip
      G01065933Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 4: Separating Motor Generator No. 1 From Motor Generator No. 2
      G01065932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver and a hammer, disconnect the MG1 assembly from the MG2 assembly.
  3. Remove the counter driven gear assembly from the MG2 assembly.
    Fig 5: Identifying Input Shaft Assembly, Counter Driven Gear & Differential Case Assembly
    G01065934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Remove the differential case assembly from the MG2 assembly.
    Fig 6: Identifying Input Shaft Assembly & Differential Case Assembly
    G01065935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Remove 2 race and needle roller bearing  .
    Fig 7: Identifying 2 Race & Needle Roller Bearing (Input Shaft To Ring Gear)
    G01065936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Remove drive sprocket sub-assembly and chain  .
    Fig 8: Identifying Chain & Drive Sprocket
    G01065937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Remove input shaft assembly  :
    1. Remove the input shaft assembly.
      Fig 9: Identifying Input Shaft Assembly
      G01065938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the needle roller bearing and 2 bearing races.
      Fig 10: Identifying 2 Race & Needle Roller Bearing (Drive Sprocket To Input Shaft)
      G01065939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. Remove planetary ring gear  .
    Fig 11: Identifying Planetary Ring Gear
    G01065940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. Remove ring gear flange and shim  .
    Fig 12: Identifying Ring Gear Flange & Shim
    G01065941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. NOTE: Remove the counter drive gear by tapping the case with a plastic hammer.
    Fig 13: Removing Counter Drive Gear & Shim
    G01065942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. Remove counter drive gear and shim  .
  11. Remove oil pan and gasket  :
    1. Remove the drain plug and its gasket.
    2. Remove the 12 bolts.
      Fig 14: Identifying Transaxle Oil Pan
      G01065943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the oil pan and its gasket.
  12. Remove magnet from oil pan  .
    Fig 15: Identifying Transaxle Oil Pan Magnet
    G01065944Courtesy 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.

    • Steel (magnetic): bearing, gear and plate wear
    • Brass (non-magnetic): bushing wear
  14. Remove oil strainer  :
    1. Remove the bolt and oil strainer.
      Fig 16: Identifying Transaxle Oil Strainer Bolt
      G01065946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the "O" ring from the oil strainer.
      Fig 17: Identifying Transaxle Oil Strainer & "O" Ring
      G01065947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. Set MG2 assembly and wood blocks  . See Fig 18.
    Fig 18: Placing Motor Generator 2 On Wood Blocks
    G01065948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. Remove the 3 bolts and mounting bracket.
    Fig 19: Locating Motor Generator 2 Mounting Bracket Bolts
    G01065949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. Remove the 2 bolts and the 2 wiring harness connectors (MG2 side).
    Fig 20: Identifying Wiring Harness Connectors (MG2 Side)
    G01065950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. Remove 2 water jacket unions (MG2 Side)  .
    Fig 21: Identifying Water Jacket Unions (MG2 Side)
    G01065951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. Remove the 6 bolts and parking cover.
    Fig 22: Identifying Parking Cover & Bolts
    G01065952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. Remove the bolt, detent spring cover and detent spring.
    Fig 23: Locating Detent Spring Bolt
    G01065953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. Remove the 6 bolts and motor water jacket cover.
    Fig 24: Identifying Motor Generator 2 Water Jacket Cover & Bolts
    G01065954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. Remove parking shaft cover  :
    1. Remove the 5 bolts and parking shaft cover.
      Fig 25: Identifying Motor Generator 2 Parking Shaft Cover & Bolts
      G01065955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, remove the oil seal from the cover.
      Fig 26: Removing Parking Shaft Cover Oil Seal
      G01065956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. Remove parking lock shaft assembly  .
    Fig 27: Locating Parking Lock Shaft
    G01065957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. Disassemble parking lock shaft assembly  :
    1. Remove the washer.
      Fig 28: Identifying Parking Lock Shaft & Washer
      G01065958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a chisel and a hammer, cut the spacer.
      Fig 29: Cutting Spacer With Chisel & Hammer
      G01065959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the spacer.
    4. Using a pin punch and a hammer, drive out the pin.
      Fig 30: Punching Roll Pin Out
      G01065960Courtesy 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 31: Identifying Oil Pump Cover Plug & Plug "O" Ring
      G01065961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 5 bolts and oil pump cover.
      Fig 32: Identifying Oil Pump Cover & Bolts
      G01065962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the "O" ring.
      Fig 33: Identifying Oil Pump Cover "O" Ring
      G01065963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the oil pump driven rotor and drive rotor.
      Fig 34: Identifying Oil Pump Driven Rotor & Drive Rotor
      G01065964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the oil pump drive shaft.
      Fig 35: Identifying Oil Pump Drive Shaft
      G01065965Courtesy 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. SST 09308-00010.

    Fig 36: Pulling Differential Side Bearing Outer Race LH & Shim (MG2 Side)
    G01065966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 37: Pulling Counter Driven Gear Side Bearing Outer Race & Shim
      G01065967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. CAUTION: Be careful not to bend the parking lock rod.
      Fig 38: Placing MG2 On Wood Blocks
      G01065968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Overturn the MG2 assembly and place wood blocks under to stabilize.
  28. Remove differential oil seal LH (MG2 side)  .

    Using a screwdriver, drive out the oil seal.

    Fig 39: Prying Left Side Differential Oil Seal Out (MG2 Side)
    G01065969Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. Remove filler plug and screw plug (MG2 side)  :
    1. Remove the 2 screw plugs with a hexagon wrench.
      Fig 40: Identifying Filler Plugs & Screw Plugs (MG2 Side)
      G01065970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 filler plugs and the 2 gaskets.
  30. Remove breather plug  .
    Fig 41: Locating Breather Plug
    G01065971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. Place wood block under MG1 assembly to stabilize  .
    Fig 42: Placing Wooden Blocks Under Motor Generator No. 1 Assembly
    G01065972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. Remove high-voltage cable  :
    1. Remove the 4 bolts and power cable cover.
      Fig 43: Locating Power Cable Cover Bolts
      G01065973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 6 bolts and the high-voltage cables.
      Fig 44: Identifying High Voltage Cable Securing & Terminal Bolts
      G01065974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. Remove the bolt and wiring harness connector (MG1 side).
    Fig 45: Identifying Wiring Harness Connector (MG1 Assembly)
    G01065975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. Remove 2 water jacket unions (MG1 Side)  .
    Fig 46: Identifying Water Jacket Unions (MG1 Assembly)
    G01065976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. Remove housing tube  .
    Fig 47: Identifying Housing Tube (MG1 Assembly)
    G01065977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. Remove input shaft oil seal  .

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

    Fig 48: Pulling Input Shaft Oil Seal Out
    G01065978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. Remove differential oil seal RH (MG1 Side)  .

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

    Fig 49: Prying Right Side Differential Oil Seal Out (MG1 Assembly)
    G01065979Courtesy 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 50: Identifying Lock Clamp Bolt
      G01065980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the parking lock pawl shaft.
    3. Remove the parking lock pawl.
      Fig 51: Identifying Parking Lock Pawl & Pawl Shaft
      G01065981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. Remove parking lock sleeve  :
    1. Remove the 2 bolts, sleeve bracket, torsion spring and parking lock sleeve.
      Fig 52: Locating Parking Lock Sleeve, Sleeve Bracket & Mounting Bolts
      G01065982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the cam guide sleeve from the sleeve bracket.
      Fig 53: Identifying Cam Guide Sleeve & Sleeve Bracket
      G01065983Courtesy 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 54: Pulling Right Side Counter Driven Gear Side Bearing Outer Race (MG1 Assembly)
    G01065984Courtesy 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 55: Pulling Right Side Differential Side Bearing Outer Race (MG1 Assembly)
    G01065985Courtesy 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. Remove the drain plug and the gasket.
      Fig 56: Identifying Drain & Screw Plugs (MG1 Assembly)
      G01065986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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