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Hybrid Transaxle Assembly: Disassembly

  1. INSTALL ENGINE HANGER 

    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 
    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: Installing Engine Hanger
      G03431044Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE MG1 ASSEMBLY 
    1. Remove the 21 bolts.
      Fig 2: Removing Bolts
      G03431045Courtesy 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 Using Screwdriver & Hammer
      G03431046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      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: Separating MG1 Assembly From MG2 Assembly Using Screwdriver
      G03431047Courtesy 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
    G03431048Courtesy 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
    G03431049Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE 2 RACE AND NEEDLE ROLLER BEARING 
    Fig 7: Removing Race & Needle Roller Bearing
    G03431050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE DRIVE SPROCKET SUB-ASSEMBLY AND CHAIN 
    Fig 8: Removing Drive Sprocket Sub-Assembly & Chain
    G03431051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE INPUT SHAFT ASSEMBLY 
    1. Remove the input shaft assembly.
      Fig 9: Removing Input Shaft Assembly
      G03431052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the needle roller bearing and 2 bearing races.
      Fig 10: Removing Needle Roller Bearing & Bearing Races
      G03431053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE PLANETARY RING GEAR 
    Fig 11: Removing Planetary Ring Gear
    G03431054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE RING GEAR FLANGE AND SHIM 
    Fig 12: Removing Ring Gear Flange & Shim
    G03431055Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE COUNTER DRIVE GEAR AND SHIM 

    HINT:

    Remove the counter drive gear by tapping the case with a plastic hammer.

    Fig 13: Removing Counter Drive Gear & Shim
    G03431056Courtesy 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 & Gasket
      G03431057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE MAGNET FROM OIL PAN 
    Fig 15: Removing Magnet From Oil Pan
    G03431058Courtesy 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
      Fig 16: Collecting Steel Chips Using Magnet
      G03431059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE OIL STRAINER 
    1. Remove the bolt and oil strainer.
      Fig 17: Removing Oil Strainer
      G03431060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring from the oil strainer.
      Fig 18: Removing O-Ring From Oil Strainer
      G03431061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. SET MG2 ASSEMBLY 

    Set the MG2 assembly and wood blocks.

    Fig 19: Placing MG2 Assembly On Wood Blocks
    G03431062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE MOUNTING BRACKET 

    Remove the 3 bolts and mounting bracket.

    Fig 20: Removing Mounting Bracket
    G03431063Courtesy 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
    G03431064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE 2 WATER JACKET UNIONS (MG2 side) 
    Fig 22: Removing Water Jacket Unions
    G03431065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE PARKING COVER 

    Remove the 6 bolts and parking cover.

    Fig 23: Removing Parking Cover
    G03431066Courtesy 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 Detent Spring Cover & Detent Spring
    G03431067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE MOTOR WATER JACKET COVER 

    Remove the 6 bolts and motor water jacket cover.

    Fig 25: Removing Motor Water Jacket Cover
    G03431068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE PARKING SHAFT COVER 
    1. Remove the 5 bolts and parking shaft cover.
      Fig 26: Removing Parking Shaft Cover
      G03431069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, remove the oil seal from the cover.
      Fig 27: Removing Oil Seal From Cover Using Screwdriver
      G03431070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE PARKING LOCK SHAFT ASSEMBLY 
    Fig 28: Removing Parking Lock Shaft Assembly
    G03431071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. DISASSEMBLE PARKING LOCK SHAFT ASSEMBLY 
    1. Remove the washer.
      Fig 29: Removing Washer
      G03431072Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a chisel and a hammer, cut the spacer.
      Fig 30: Cutting Spacer Using Chisel & Hammer
      G03431073Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the spacer.
    4. Using a pin punch and a hammer, drive out the pin.
      Fig 31: Driving Out Pin Using Pin Punch & Hammer
      G03431074Courtesy 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
      G03431075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 5 bolts and oil pump cover.
      Fig 33: Removing Oil Pump Cover
      G03431076Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the O-ring.
      Fig 34: Removing O-Ring
      G03431077Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the oil pump driven rotor and drive rotor.
      Fig 35: Removing Oil Pump Driven Rotor & Drive Rotor
      G03431078Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the oil pump drive shaft.
      Fig 36: Removing Oil Pump Drive Shaft
      G03431079Courtesy 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 37: Driving Out Differential Side Bearing Outer Race & Shim Using SST
    G03431080Courtesy 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 38: Driving Out Counter Driven Gear Side Bearing Outer Race & Shim Using SST
      G03431081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Overturn the MG2 assembly and place a wood block under it stabilize.
      NOTE: Be careful not to bend the parking lock rod. 
      Fig 39: Placing MG2 Assembly On Wood Block
      G03431082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE DIFFERENTIAL OIL SEAL LH (MG2 side) 

    Using a screwdriver, drive out the oil seal.

    Fig 40: Driving Out Oil Seal Using Screwdriver
    G03431083Courtesy 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. Remove the 2 filler plugs and the 2 gaskets.
      Fig 41: Removing Filler Plugs & Screw Plugs
      G03431084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE BREATHER PLUG 
    Fig 42: Removing Breather Plug
    G03431085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. PLACE WOOD BLOCK UNDER MG1 ASSEMBLY TO STABILIZE 
    Fig 43: Placing Wood Block Under MG1 Assembly
    G03431086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE HIGH-VOLTAGE CABLE 
    1. Remove the 4 bolts and power cable cover.
      Fig 44: Removing Power Cable Cover
      G03431087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 6 bolts and the high-voltage cable.
      Fig 45: Removing High-Voltage Cable
      G03431088Courtesy 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
    G03431089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE 2 WATER JACKET UNIONS (MG1 side) 
    Fig 47: Removing Water Jacket Unions
    G03431090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE HOUSING TUBE 
    Fig 48: Removing Housing Tube
    G03431091Courtesy 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: Driving Out Input Shaft Oil Seal Using SST
    G03431092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE DIFFERENTIAL OIL SEAL RH (MG1 side) 

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

  38. TURN MG1 ASSEMBLY UPSIDE DOWN 
    Fig 50: Driving Out Differential Oil Seal RH Using Screwdriver
    G03431093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE PARKING LOCK PAWL 
    1. Remove the bolt and the lock clamp.
      Fig 51: Removing Lock Clamp
      G03431094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the parking lock pawl shaft.
    3. Remove the parking lock pawl.
      Fig 52: Removing Parking Lock Pawl Shaft & Parking Lock Pawl
      G03431095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE PARKING LOCK SLEEVE 
    1. Remove the 2 bolts, sleeve bracket, torsion spring and parking lock sleeve.
      Fig 53: Removing Bolts, Sleeve Bracket, Torsion Spring & Parking Lock Sleeve
      G03431096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the cam guide sleeve from the sleeve bracket.
      Fig 54: Removing Cam Guide Sleeve From Sleeve Bracket
      G03431097Courtesy 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: Driving Out Counter Driven Gear Side Bearing Outer Race RH Using SST
    G03431098Courtesy 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: Driving Out Differential Side Bearing Outer Race RH Using SST
    G03431099Courtesy 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 57: Removing Drain Plug
      G03431100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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