Part 1
HYBRID VEHICLE TRANSAXLE ASSYOVERHAUL
NOTICE:
^ When working on the high voltage systems, always wear insulated gloves.
^ After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU.
^ 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.
1. REMOVE HYBRID VEHICLE TRANSAXLE ASSY
2. REMOVE HYBRID VEHICLE GENERATOR ASSY
a. Install the engine hanger in the position shown in the illustration.
HINT:
^ Engine hanger 12281-67070, S1228-11781
^ Bolt 91642-81045, 91642-81265
^ Nut 90178-10001, 90179-12147
b. Using an engine sling device and chain block, set the transaxle assy with the generator side facing upward.
NOTICE:
^ Fix the transaxle assy on a wooden block, etc.
^ Fix the transaxle assy so that no excessive force is applied to the cable.
c. Remove the drain plug.
d. Remove the 21 bolts shown in the illustration.
HINT:
^ 13 bolts on the generator assy side.
^ 8 bolts on the motor assy side.
e. Separate the motor assy and generator assy by inserting a flat-head screwdriver in the position shown and prying the two apart.
NOTICE: Be careful not to damage the two faces of each part.
f. Using an engine sliding device and a chain block, raise the generator assy.
HINT: Raise the generator assy approximately 3 to 4 cm.
g. Apply protective tape to the head of a flat-head screwdriver and use it to hold down the chain with input shaft assy while removing the generator assy.
3. REMOVE DIFFERENTIAL DRIVE PINION
a. Remove the counter driven gear from the HV motor.
4. REMOVE DIFFERENTIAL CASE ASSY
a. Remove the differential case assy from the HV motor.
5. REMOVE TRANSMISSION DRIVE SPROCKET SUB-ASSY
a. Remove the thrust bearing race, thrust needle roller bearing and thrust bearing race No.1.
HINT: The thrust bearing race may be attached to the generator assy side.
b. Remove the drive sprocket and chain.
6. REMOVE INPUT SHAFT ASSY
a. Remove the input shaft assy.
7. REMOVE PLANETARY RING GEAR
a. Remove the thrust bearing race, thrust needle roller bearing and thrust bearing race No.1.
HINT: The thrust bearing race may be attached to the input shaft side.
b. Remove the planetary ring rear.
8. REMOVE PLANETARY RING GEAR FLANGE
a. Remove the planetary ring gear flange and shim.
9. REMOVE SPROCKET DRIVEN & COUNTER DRIVE GEAR
a. Use a plastic hammer to tap the motor assy case and remove the counter drive gear and shim.
HINT: Remove the counter drive gear while pulling it vertically.
10. REMOVE TRANSMISSION OIL STRAINER
a. Remove the bolt and oil strainer.
b. Remove the O-ring from the oil strainer.
11. REMOVE HV MOTOR ASSY
a. Fix the motor assy on a wooden block, etc.
12. REMOVE ENGINE MOUNTING BRACKET NO.3
a. Remove the 3 bolts and mounting bracket.
13. REMOVE MOTOR REVOLUTION SENSOR WIRING HARNESS CONNECTOR
a. Remove the bolt and pull out the HV motor side motor revolution sensor wire harness connector (gray).
NOTICE: Do not pull on the connector any more then necessary.
b. Remove the connector and motor revolution sensor wire harness connector (gray).
14. REMOVE MOTOR STATOR WIRING HARNESS CONNECTOR
a. Remove the bolt and pull out the motor stator wire harness connector (black).
NOTICE: Do not pull on the sensor connector any more then necessary.
b. Remove the connector and the motor stator wire harness connector (black).
15. REMOVE SHIFT CONTROL ACTUATOR ASSY
a. Remove the 3 bolts and shift control actuator assy.
16. REMOVE PARKING COVER
a. Remove the 6 bolts and the parking cover.
17. REMOVE MANUAL DETENT SPRING SUB-ASSY
a. Remove the bolt, manual detent spring cover and manual detent spring.
18. REMOVE MOTOR WATER JACKET COVER
a. Remove the 6 bolts and motor water jacket cover.
19. REMOVE PARKING SHAFT COVER
a. Remove the 5 bolts and the parking shaft cover.
20. REMOVE TRANSMISSION OIL PUMP COVER SUB-ASSY
a. Remove the oil pump cover plug and O-ring.
b. Remove the 5 bolts and oil pump cover.
c. Remove the O-ring.
21. REMOVE OIL PUMP DRIVE SHAFT
a. Remove the oil pump drive rotor and oil pump driven rotor.
b. Remove the oil pump drive shaft.
22. REMOVE DIFFERENTIAL CASE LH TAPERED ROLLER BEARING
a. Using SST, remove the differential case tapered roller bearing LH outer race and shim.
SST 09308-00010
23. REMOVE HYBRID VEHICLE TRANSAXLE ASSY TYPE T OIL SEAL
a. Fix the motor assy on a wooden block, etc.
NOTICE: Do not use a wooden block with the parking lock rod.
b. Using SST, remove the oil seal.
SST 09308-00010
24. REMOVE TRANSAXLE HOUSING & CASE W/HEAD STRAIGHT SCREW PLUG
a. Remove the set plug and gasket.
b. Using a hexagon wrench (10 mm), remove the screw plugs.
25. FIX HYBRID VEHICLE GENERATOR ASSY
a. Fix the generator assy on a wooden block, etc.
26. REMOVE POWER CABLE COVER
a. Remove the breather plug.
b. Remove the 4 bolts and power cable cover.
27. REMOVE GENERATOR CABLE
a. Remove the 5 bolts and generator cable.
28. REMOVE GENERATOR MOTOR REVOLUTION SENSOR WIRING HARNESS CONNECTOR
a. Remove the bolt and pull out the HV generator side generator revolution sensor wire harness connector.
NOTICE: Do not pull on the sensor connector any more than necessary.
b. Disconnect the connector and the HV generator side generator revolution sensor wire harness connector.
29. REMOVE TRANSAXLE HOUSING TUBE CONNECTOR
a. Remove the transaxle housing tube connector.
30. REMOVE HYBRID VEHICLE TRANSAXLE ASSY TYPE T OIL SEAL
a. Using SST, remove the oil seal.
SST 09612-30012
31. REMOVE HYBRID VEHICLE TRANSAXLE ASSY TYPE T OIL SEAL
a. Using SST, remove the oil seal.
SST 09308-00010
32. REMOVE DIFFERENTIAL CASE RH TAPERED ROLLER BEARING
a. Using SST, remove the differential case tapered roller bearing LH outer race.
SST 09308-00010
33. REMOVE TRANSAXLE HOUSING & CASE W/HEAD STRAIGHT SCREW PLUG
a. Remove the set plug and gasket.
b. Using a socket wrench (6 mm), remove the screw plug.