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Hybrid Transaxle Assembly: Reassembly

  1. INSPECT ROTOR BUSH OF MG2 ASSEMBLY 

    Using a dial indicator, measure the inside diameter of the rotor bush.

    Standard diameter: 

    • 20.025 - 20.046 mm (0.78838 - 0.78921 in.) 

    Maximum diameter: 

    • 20.096 mm (0.79118 in.) 

    If the inside diameter exceeds the limit, replace the MG2 assembly.

    Fig 1: Measuring Inside Diameter Of Rotor Bush Using Dial Indicator
    G03431101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. PLACE WOOD BLOCK UNDER MG1 ASSEMBLY TO STABILIZE 
    Fig 2: Placing Wood Block Under MG1 Assembly
    G03431102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL DRAIN PLUG AND SCREW PLUG (MG1 side) 
    1. Apply liquid sealer to the screw plug and install it to the MG1 assembly with a hexagon wrench.

      Sealant: 

      • Part No. 08833-00080, TREE BOND 1344, LOCTITE 242 or equivalent 

      Torque:  12.7 N.m (130 kgf.cm, 9 ft.lbf)

    2. Install a new gasket and the drain plug.

      Torque:  39 N.m (400 kgf.cm, 29 ft.lbf)

      Fig 3: Installing Drain Plug & Screw Plug (MG1 Side)
      G03431103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. PLACE WOOD BLOCK UNDER MG2 ASSEMBLY 
    NOTE: Be careful not to bend the parking lock rod. 
    Fig 4: Placing Wood Block Under MG2 Assembly
    G03431104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FILLER PLUG AND SCREW PLUG (MG2 side) 
    1. Apply liquid sealer to the 2 screw plugs and install them to the MG2 assembly with a hexagon wrench.

      Sealant: 

      • A:  Part No. 08833-00070, THREE BOND 1324 or equivalent
      • B:  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

      Torque:  24.5 N.m (250 kgf.cm, 18 ft.lbf)

      NOTE: Be careful not to bend the parking lock rod. 
    2. Install 2 new gaskets and the 2 filler plugs.

      Torque:  39 N.m (400 kgf.cm, 29 ft.lbf)

      Fig 5: Installing Filler Plug & Screw Plug (MG2 Side)
      G03431105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL DIFFERENTIAL OIL SEAL RH (MG1 side) 
    1. Using SST and a hammer, install a new oil seal.

      SST 09710-20011 (09710-06071), 09950-70010 (09951-07100)

      Oil seal depth:  2.7 +/- 0.5 mm (0.106 +/- 0.020 in.)

    2. Coat the lip of the oil seal with MP grease.
      Fig 6: Installing Oil Seal Using SST & Hammer
      G03431106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL DIFFERENTIAL OIL SEAL LH (MG2 side) 
    1. Using SST and a hammer, install a new oil seal LHs.

      SST 09710-20011 (09710-06071), 09950-70010 (09951-07100)

      Oil seal depth:  2.7 +/- 0.5 mm (0.106 +/- 0.020 in.)

    2. Coat the lip of the oil seal with MP grease.
      Fig 7: Installing Oil Seal LH Using SST & Hammer
      G03431107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL BREATHER PLUG 

    Torque:  11.3 N.m (111 kgf.cm, 8 ft.lbf)

    Fig 8: Installing Breather Plug
    G03431108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL OUTER RACE AND SHIM 

    HINT:

    If there is some deformation or scratch to the outer race and shim, replace each of them by a new one.

    1. Place a wood block under the MG2 assembly to stabilize.
      NOTE:
      • Set the MG2 assembly horizontally. 
      • Unreasonable force should not be applied to the high-voltage cable. 
        Fig 9: Placing Wood Block Under MG2 Assembly
        G03431109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. MG2 side:

      Using SST and a hammer, install the outer race of differential side bearing LH and shim.

      SST 09950-60020 (09951-00680), 09950-70010 (09951-07100)

      HINT:

      If replacing the shim, install a new shim which has the same thickness with the removed.

      Fig 10: Installing Outer Race Of Differential Side Bearing LH & Shim Using SST & Hammer
      G03431110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. MG2 side:

      Using SST and a hammer, install the tapered roller bearing outer race LH of the counter driven gear and shim.

      SST 09950-60020 (09951-00680), 09950-70010 (09951-07100)

      HINT:

      If replacing the shim, install a new shim which has the same thickness with the removed.

      Fig 11: Installing Tapered Roller Bearing Outer Race LH Of Counter Driven Gear & Shim Using SST & Hammer
      G03431111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. MG1 side:

      Using SST and a hammer, install the side bearing outer race RH of the differential.

      SST 09950-60020 (09951-00680), 09950-70010 (09951-07100)

      Fig 12: Installing Side Bearing Outer Race RH Of Differential Using SST & Hammer
      G03431112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. MG1 side:

      Using SST and a hammer, install the tapered roller bearing outer race RH of the counter driven gear.

      SST 09950-60020 (09951-00680), 09950-70010 (09951-07100)

      Fig 13: Installing Tapered Roller Bearing Outer Race RH Of Counter Driven Gear Using SST & Hammer
      G03431113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL DIFFERENTIAL TO MG2 ASSEMBLY 
    1. Install the differential assembly to the MG2 assembly.

      HINT:

      Apply ATF to the side bearing.

      Fig 14: Installing Differential Assembly To MG2 Assembly
      G03431114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the engine hanger onto the MG1 side as shown in Fig 15, 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 15: Installing Engine Hanger Onto MG1
      G03431115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 13 bolts and MG1 assembly to the MG2 assembly.

      Torque:  25 N.m (250 kgf.cm, 18 ft.lbf)

      Fig 16: Installing MG1 Assembly To MG2 Assembly
      G03431116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, rotate the differential case assembly in both directions to make it fit.

      SST 09564-3201 1

      Fig 17: Rotating Differential Case Assembly Using SST
      G03431117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST and a small torque wrench, measure the differential preload.

      SST 09564-3201 1

      Preload (Starting torque): 

      New bearing 

      • 0.98 - 1.57 N.m (9.99 - 16.01 kgf.cm, 8.67 - 13.90 in.lbf) 

      Reused bearing 

      • 0.49 - 0.78 N.m (5.00 - 7.95 kgf.cm, 4.34 - 6.90 in.lbf) 

      Preload (Turning torque): 

      • 0.78 - 1.37 N.m (60 rpm) (7.95 - 13.97 kgf.cm, 6.90 - 12.13 in.lbf) 
      Fig 18: Measuring Differential Preload Using SST & Torque Wrench
      G03431118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the preload is not within the specified range, replace the shim of the differential outer race LH.

      Shim thickness: 

      SHIM THICKNESS SPECIFICATIONS

      Mark Thickness mm (in.) Mark Thickness mm (in.)
      1 1.80 (0.0709) 61 2.14 (0.0843)
      2 1.83 (0.0720) 62 2.16 (0.0850)
      3 1.86 (0.0732) 63 2.18 (0.0858)
      4 1.89 (0.0744) 64 2.20 (0.0866)
      50 1.92 (0.0756) 65 2.22 (0.0874)
      51 1.94 (0.0764) 66 2.24 (0.0882)
      52 1.96 (0.0772) 67 2.26 (0.0890)
      53 1.98 (0.0780) 68 2.28 (0.0898)
      54 2.00 (0.0787) 69 2.30 (0.0906)
      55 2.02 (0.0795) 70 2.32 (0.0913)
      56 2.04 (0.0803) 19 2.34 (0.0921)
      57 2.06 (0.0811) 20 2.37 (0.0933)
      58 2.08 (0.0819) - 2.40 (0.0945)
      59 2.10 (0.0827) 22 2.43 (0.0957)
      60 2.12 (0.0835) 23 2.46 (0.0969)

      HINT:

      As a rank of shim thickness is increased (0.020 mm), the preload of approx. 0.23 N.m (2.4 kgf.cm, 2.1 in.lbf) is increased accordingly.

  11. INSTALL COUNTER DRIVEN GEAR TO MG2 ASSEMBLY 
    1. Remove the 13 bolts, separate the MG1 assembly and the MG2 assembly.
    2. Install the counter driven gear to the MG2 assembly.

      HINT:

      Apply ATF to the side bearing.

      Fig 19: Installing Counter Driven Gear To MG2 Assembly
      G03431119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the engine hanger onto the MG1 side as shown in Fig 20, 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 20: Installing Engine Hanger Onto MG1
      G03431120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the MG1 assembly to the MG2 assembly with the 13 bolts.

      Torque:  25 N.m (250 kgf.cm, 18 ft.lbf)

      Fig 21: Installing MG1 Assembly To MG2 Assembly
      G03431121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST, rotate the differential case assembly in both directions to make it fit.

      SST 09564-3201 1

      Fig 22: Rotating Differential Case Assembly Using SST
      G03431122Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using SST and a small torque wrench, measure the counter driven gear preload.

      SST 09564-3201 1

      Preload (Starting torque): 

      New bearing 

      • 3.81 - 6.10 N.m (38.85 - 62.20 kgf.cm, 33.72 - 53.99 in.lbf) 

      Reused bearing 

      • 1.91 - 3.03 N.m (19.48 - 30.90 kgf.cm, 16.91 - 26.82 in.lbf) 

      Preload (Turning torque): 

      • 3.29 - 6.66 N.m (60 rpm) (33.55 - 67.91 kgf.cm, 29.12 - 58.95 in.lbf) 
      Fig 23: Measuring Counter Driven Gear Preload Using SST & Torque Wrench
      G03431123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the preload is not within the specified range, replace the shim of the counter driven gear LH.

      Shim thickness: 

      SHIM THICKNESS SPECIFICATIONS

      Mark Thickness mm (in.) Mark Thickness mm (in.)
      1 1.25 (0.0492) 62 1.58 (0.0622)
      2 1.28 (0.0504) 63 1.60 (0.0630)
      3 1.31 (0.0516) 64 1.62 (0.0638)
      50 1.34 (0.0528) 65 1.64 (0.0646)
      51 1.36 (0.0535) 66 1.66 (0.0654)
      52 1.38 (0.0543) 67 1.68 (0.0661)
      53 1.40 (0.0551) 68 1.70 (0.0669)
      54 1.42 (0.0559) 69 1.72 (0.0677)
      55 1.44 (0.0567) 70 1.74 (0.0685)
      56 1.46 (0.0575) 18 1.76 (0.0693)
      57 1.48 (0.0583) 19 1.79 (0.0705)
      58 1.50 (0.0591) 20 1.82 (0.0717)
      59 1.52 (0.0598) 21 1.85 (0.0728)
      60 1.54 (0.0606) 22 1.88 (0.0740)
      61 1.56 (0.0614) - -

      HINT:

      As a rank of shim thickness is increased (0.020 mm) the preload of approx. 1.1 N.m (11.2 kgf.cm, 9.7 in.lbf) is increased accordingly.

  12. REMOVE 13 BOLTS, SEPARATE MG1 ASSEMBLY AND MG2 ASSEMBLY 
  13. ADJUST SHIM 
    1. Install the 2 bearing races and needle roller bearing to the MG1 assembly.
      Fig 24: Installing Bearing Races & Needle Roller Bearing To MG1 Assembly
      G03431124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the drive sprocket assembly to the MG1 assembly.
      Fig 25: Installing Drive Sprocket Assembly To MG1 Assembly
      G03431125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the input shaft assembly.
      Fig 26: Installing Input Shaft Assembly
      G03431126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the 2 bearing races and needle roller bearing.
      Fig 27: Installing Bearing Races & Needle Roller Bearing
      G03431127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the planetary ring gear.
      Fig 28: Installing Planetary Ring Gear
      G03431128Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the ring gear flange.
      Fig 29: Installing Ring Gear Flange
      G03431129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a straight edge and vernier calipers, measure the dimension "A" and "B" correctly.
    8. Select a shim that will ensure that the value is within the specification.

      Shim thickness: 

      • Dimension "B" - Dimension "A" 
      SHIM THICKNESS SPECIFICATIONS

      Mark Thickness mm (in.) Mark Thickness mm (in.)
      1 1.00 (0.0394) 7 2.20 (0.0866)
      2 1.20 (0.0472) 8 2.40 (0.0945)
      3 1.40 (0.0551) 9 2.60 (0.1024)
      4 1.60 (0.0630) 10 2.80 (0.1102)
      5 1.80 (0.0709) 11 3.00 (0.1181)
      6 2.00 (0.0787) 12 3.20 (0.1260)
      Fig 30: Measuring Dimension A & B Using Straight Edge & Vernier Calipers
      G03431130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Install the counter drive gear assembly to the MG1 assembly.
      Fig 31: Installing Counter Drive Gear Assembly To MG1 Assembly
      G03431131Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Using a straight edge and vernier calipers, measure the dimension "A" and "B" correctly.
    11. Select a shim thickness is surely within the specified range.

      Shim thickness: 

      • Dimension "B" - Dimension "A" 
      SHIM THICKNESS SPECIFICATIONS

      Mark Thickness mm (in.) Mark Thickness mm (in.)
      A 1.35 (0.0531) G 1.65 (0.0650)
      B 1.40 (0.0551) H 1.70 (0.0669)
      C 1.45 (0.0571) J 1.75 (0.0689)
      D 1.50 (0.0591) K 1.80 (0.0709)
      E 1.55 (0.0610) L 1.85 (0.0728)
      F 1.60 (0.0630) - -
      Fig 32: Measuring Dimension A & B Using Straight Edge & Vernier Calipers
      G03431132Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL INPUT SHAFT ASSEMBLY TO MG2 ASSEMBLY 
    1. Install the shim selected in step  13 (h).
      Fig 33: Installing Shim
      G03431133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the ring gear flange.
    3. Install the 2 races and thrust bearing.

      HINT:

      Apply ATF to the thrust bearing.

      Fig 34: Installing Races, Thrust Bearing & Ring Gear Flange
      G03431134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the planetary ring gear.
      Fig 35: Installing Planetary Ring Gear
      G03431135Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the input shaft assembly.
      Fig 36: Installing Input Shaft Assembly
      G03431136Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL COUNTER DRIVE GEAR ASSEMBLY, CHAIN AND DRIVE SPROCKET ASSEMBLY 
    1. Install the shim selected in step  13 (k).
      Fig 37: Installing Shim
      G03431137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the counter drive gear assembly and chain at the same time.
      NOTE: Install the chain with the mark plate facing up. 
      Fig 38: Installing Counter Drive Gear Assembly & Chain
      G03431138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Put the chain on the drive sprocket and install them.

      HINT:

      Apply ATF to the drive sprocket needle roller bearing.

      Fig 39: Installing Chain On Drive Sprocket
      G03431139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the 2 bearing races and needle roller bearing.

      HINT:

      Apply ATF to the thrust bearing.

      Fig 40: Installing Bearing Races & Needle Roller Bearing
      G03431140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL PARKING LOCK PAWL TO MG1 ASSEMBLY 
    1. Install the lock sleeve.
      Fig 41: Installing Lock Sleeve
      G03431141Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the cam guide sleeve to the sleeve bracket.
      Fig 42: Installing Cam Guide Sleeve To Sleeve Bracket
      G03431142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the cam guide sleeve, sleeve bracket, torsion spring and 2 bolts.

      Torque:  13 N.m (130 kgf.cm, 9 ft.lbf)

      Fig 43: Installing Cam Guide Sleeve, Sleeve Bracket, Torsion Spring & Bolts
      G03431143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the parking lock pawl
    5. Using a screw driver, fit the torsion spring into a cut-out of the parking lock pawl.
      Fig 44: Fitting Torsion Spring Into Cut-Out Of Parking Lock Pawl Using Screw Driver
      G03431144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the parking lock pawl shaft, lock clamp and bolt.

      Torque:  5.4 N.m (55 kgf.cm, 48 in.lbf)

      Fig 45: Installing Parking Lock Pawl Shaft, Lock Clamp & Bolt
      G03431145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL OIL PAN (MG2 side) 
    1. Install a new O-ring to the oil strainer.
      Fig 46: Installing O-Ring To Oil Strainer
      G03431146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the bolt and oil strainer.

      Torque:  5.5 N.m (56 kgf.cm, 49 in.lbf)

      Fig 47: Installing Bolt & Oil Strainer
      G03431147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the magnet to the oil pan.
      Fig 48: Installing Magnet To Oil Pan
      G03431148Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Apply liquid sealer to 2 or 3 threads of the bolt end.

      Sealant:  Part No. 08833-00080, THREE BOND 2430, LOCTITE 204 or equivalent

    5. Install a new gasket and the oil pan with the 12 bolts.

      Torque:  7.6 N.m (77 kgf.cm, 67 in.lbf)

    6. Install a new gasket and drain plug.

      Torque:  49 N.m (498 kgf.cm, 36 ft.lbf)

      Fig 49: Installing Gasket
      G03431149Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL MG1 ASSEMBLY TO MG2 ASSEMBLY 
    1. Apply FIPG to the MG2 assembly as shown in Fig 50.

      FIPG:  Part No. 08826 - 00090, THREE BOND 1281 or equivalent

    2. Install the MG1 to the MG2 (See REASSEMBLY ).
      Fig 50: Identifying FIPG Application Surface Of MG2
      G03431150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: When putting MG2 and MG1 together, assemble them so that the parking rod is inserted into the cam guide sleeve. 
      Fig 51: Assembling MG2 & MG1
      G03431151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply liquid sealer to 2 or 3 threads of the bolt end.

      Sealant:  Part No. 08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent

    4. Install the 21 bolts.

      Torque:  25 N.m (250 kgf.cm, 18 ft.lbf)

      Fig 52: Installing Bolts
      G03431152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL OIL SEAL OF INPUT SHAFT (MG1 side) 
    1. Using SST and a hammer, install a new oil seal.

      SST 09388-40010

      Oil seal depth:  1 - 1.5 mm (0.039 - 0.059 in.)

      HINT:

      Drive in the oil seal unit SST comes into contact with the case.

    2. Coat the lip of the oil seal with MP grease.
      Fig 53: Installing Oil Seal Using SST & Hammer
      G03431153Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. SET HYBRID TRANSAXLE ASSEMBLY 

    Set the hybrid transaxle assembly as shown in Fig 54.

    Fig 54: Setting Hybrid Transaxle Assembly
    G03431154Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REASSEMBLE PARKING LOCK SHAFT ASSEMBLY 
    1. Install the parking lock lever No. 3 to the parking lock shaft.
    2. Using a pin punch and a hammer, drive in the pin.
      Fig 55: Driving Pin Using Pin Punch & Hammer
      G03431155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Turn the spacer and the lever shaft to align the small hole in the spacer with the staking position mark on the lever shaft.
    4. Using a pin punch, stake the spacer through the small hole.
    5. Check that the spacer does not turn.
      Fig 56: Staking Spacer Through Small Hole Using Pin Punch
      G03431156Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL PARKING LOCK SHAFT ASSEMBLY AND WASHER 
    1. Apply ATF to the parking lock shaft.
    2. Apply MP grease to the parking lock lever No. 3.
    3. Install the washer to the parking lock shaft assembly.
      Fig 57: Installing Washer To Parking Lock Shaft Assembly
      G03431157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL PARKING LOCK SHAFT ASSEMBLY 
    Fig 58: Installing Parking Lock Shaft Assembly
    G03431158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a hammer, install a new oil seal to the parking shaft cover.

      SST 09950-60010 (09951-00230), 09950-70010 (09951-07100)

    2. Coat the lip of the oil seal with MP grease.
    3. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the parking shaft cover and MG2 case.
      • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
      • Thoroughly clean all components to remove all the loose material.
      • Using a non-reusable solvent, clean both sealing surfaces.
        Fig 59: Installing Oil Seal To Parking Shaft Cover Using SST & Hammer
        G03431159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Apply FIPG to the parking shaft cover as shown in Fig 60.

      FIPG:  Part No. 08826 - 00090, THREE BOND 1281 or equivalent

      • Install a nozzle that has been cut to a 1.5 mm (0.06 in.) opening.
      • Parts must be assembled within 10 minutes after application. Otherwise the material must be removed and reapplied.
      • Remove the nozzle from the tube and reinstall the cap.
        Fig 60: Identifying FIPG Application Surface Of Parking Shaft Cover
        G03431160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the 5 bolts and parking shaft cover.

      Torque:  13 N.m (130 kgf.cm, 10 ft.lbf)

      NOTE: When installing the cover, be careful not to damage the lip of the oil seal. 
  24. INSTALL MOTOR WATER JACKET COVER 
    1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the motor water jacket cover and MG2 case.
      • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
      • Thoroughly clean all components to remove all the loose material.
      • Using a non-reusable solvent, clean both sealing surfaces.
        Fig 61: Installing Motor Water Jacket Cover
        G03431161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply FIPG to the motor water jacket cover as shown in Fig 62.

      FIPG:  Part No. 08826-00080 or equivalent

      • Install a nozzle that has been cut to a 1.5 mm (0.06 in.) opening.
      • Parts must be assembled within 10 minutes after application. Otherwise the material must be removed and reapplied.
      • Remove the nozzle from the tube and reinstall the cap.
        Fig 62: Identifying FIPG Application Surface Of Motor Water Jacket Cover
        G03431162Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply liquid sealer to 2 or 3 threads of the bolt end.

      Sealant:  Part No. 08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent

    4. Install the motor water jacket cover with the 6 bolts.

      Torque:  5.5 N.m (56 kgf.cm, 49 in.lbf)

      Fig 63: Installing Motor Water Jacket Cover
      G03431163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL HOUSING TUBE 
    1. Apply liquid sealer to 2 or 3 threads of the housing tube end.

      Sealant:  Part No. 08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent

    2. Install the housing tube.

      Torque:  15 N.m (152 kgf.cm, 11 ft.lbf)

      Fig 64: Installing Housing Tube
      G03431164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL PARKING COVER 
    1. Install the detent spring and detent spring cover with the bolt.

      Torque:  10 N.m (100 kgf.cm, 7 ft.lbf)

    2. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the parking cover and MG2 case.
      • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
      • Thoroughly clean all components to remove all the loose material.
      • Using a non-reusable solvent, clean both sealing surfaces.
        Fig 65: Installing Detent Spring & Detent Spring Cover With Bolt
        G03431165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply seal packing to the parking cover as shown in Fig 66.

      FIPG:  Part No. 08826 - 00090, THREE BOND 1281 or equivalent

      • Install a nozzle that has been cut to a 1.5 mm (0.06 in.) opening.
      • Parts must be assembled within 10 minutes after application. Otherwise the material must be removed and reapplied.
      • Remove the nozzle from the tube and reinstall the cap.
        Fig 66: Identifying Seal Packing Application Surface Of Parking Cover
        G03431166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the parking cover with the 6 bolts.

      Torque:  5.5 N.m (56 kgf.cm, 49 in.lbf)

      Fig 67: Installing Parking Cover
      G03431167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL OIL PUMP 
    1. Apply ATF to individual sliding parts.
    2. Install the oil pump drive shaft.
      Fig 68: Installing Oil Pump Drive Shaft
      G03431168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the oil pump driven rotor and drive rotor.
      Fig 69: Installing Oil Pump Driven Rotor & Drive Rotor
      G03431169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install a new O-ring without twisting it..
      Fig 70: Installing O-Ring
      G03431170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Apply liquid sealer to 2 or 3 threads of the bolt end.

      Sealant:  Part No. 08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent

    6. Install the oil pump cover with the 5 bolts.

      Torque:  5.5 N.m (56 kgf.cm, 49 in.lbf)

      Fig 71: Installing Oil Pump Cover
      G03431171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install a new O-ring to the plug.
    8. Install the plug.

      Torque:  7.35 N.m (75 kgf.cm, 65 in.lbf)

      Fig 72: Installing O-Ring To Plug
      G03431172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL WIRING HARNESS CONNECTOR (MG2 side) 

    Install the 2 wiring harness connectors with the 2 bolts.

    Torque:  5.5 N.m (56 kgf.cm, 49 in.lbf)

    Fig 73: Installing Wiring Harness Connectors With Bolts
    G03431173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL WIRING HARNESS CONNECTOR (MG1 side) 

    Install the wiring harness connector with the bolt.

    Torque:  5.5 N.m (56 kgf.cm, 49 in.lbf)

    Fig 74: Installing Wiring Harness Connector
    G03431174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL 4 WATER JACKET UNIONS 
    1. Apply liquid sealer to 2 or 3 threads of the union end.

      Sealant:  Part No. 08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent

    2. Install the 4 water jacket unions.

      Torque:  50 N.m (510 kgf.cm, 37 ft.lbf)

      Fig 75: Installing Water Jacket Unions
      G03431175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL HIGH-VOLTAGE CABLE 
    1. Install the high-voltage cable with the 3 bolts.

      Torque:  18 N.m (183 kgf.cm, 13 ft.lbf)

      Fig 76: Installing High-Voltage Cable
      G03431176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply liquid sealer to 2 or 3 threads of the bolt end.

      Sealant:  Part No. 08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent

    3. Install the 3 bolts.

      Torque:  5.5 N.m (56 kgf.cm, 49 in.lbf)

    4. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the power cable cover and MG1 case.
      • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
      • Thoroughly clean all components to remove all the loose material.
      • Using a non-reusable solvent, clean both sealing surfaces.
        Fig 77: Installing Bolts
        G03431177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Apply FIPG to the power cable cover as shown in Fig 78.

      FIPG:  Part No. 08826-00090, THREE BOND 1281 or equivalent

      • Install the nozzle that has been cut to a 1.5 mm (0.06 in) opening.
      • Parts must be assembled within 10 minutes after application. Otherwise the material must be removed and reapplied.
      • Remove the nozzle from the tube and reinstall the cap.
        Fig 78: Identifying FIPG Application Surface Of Power Cable Cover
        G03431178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the power cable cover with the 4 bolts.

      Torque:  4.8 N.m (48 kgf.cm, 42 in.lbf)

      Fig 79: Installing Power Cable Cover
      G03431179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL MOUNTING BRACKET 
    1. Apply liquid sealer to 2 or 3 threads of the bolt end.

      Sealant:  Part No. 08833 - 00070, THREE BOND 1324 or equivalent

    2. Install the mounting bracket with the 3 bolts.

      Torque:  52 N.m (530 kgf.cm, 38 ft.lbf)

      Fig 80: Installing Mounting Bracket
      G03431180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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