Disassembly

HYBRID TRANSMISSION / TRANSAXLE: HYBRID VEHICLE TRANSAXLE UNIT: DISASSEMBLY

DISASSEMBLY
CAUTION:
- When working on the high voltage systems, always wear insulated gloves.
- 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.
NOTE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU.

1. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY
(a) Remove the hybrid vehicle transaxle Removal.
2. REMOVE HYBRID VEHICLE GENERATOR ASSEMBLY

(a) Install the 2 engine hangers in the positions 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 with the generator side facing upward.
NOTICE:
- Place the transaxle on wooden blocks or equivalent.
- Fix the transaxle 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 side.
- 8 bolts on the motor side.

(e) Disconnect the motor and generator by inserting a flat-head screwdriver in the position shown and prying the two apart.
NOTE: Be careful not to damage the two faces of each part.

(f) Using an engine sling device and chain block, raise the generator.
HINT: Raise the generator approximately 30 to 40 mm (1.18 to 1.57 in.).

(g) Apply protective tape to the head of a flat-head screwdriver and use it to hold down the chain with input shaft while removing the generator.
3. REMOVE COUNTER DRIVEN GEAR SUB-ASSEMBLY

(a) Remove the counter driven gear from the HV motor.
4. REMOVE DIFFERENTIAL CASE ASSEMBLY

(a) Remove the differential case from the HV motor.
5. REMOVE TRANSMISSION DRIVE SPROCKET SUB-ASSEMBLY

(a) Remove the thrust bearing race, thrust needle roller bearing and No. 1 thrust bearing race.
HINT: The thrust bearing race may be attached to the generator side.

(b) Remove the drive sprocket and chain.
6. REMOVE INPUT SHAFT ASSEMBLY

(a) Remove the input shaft.
7. REMOVE PLANETARY RING GEAR

(a) Remove the thrust bearing race, thrust needle roller bearing and No. 1 thrust bearing race.
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 GEAR AND COUNTER DRIVE GEAR

(a) Using a plastic-faced hammer, tap the motor case and remove the counter drive gear and shim.
HINT: Remove the counter drive gear while pulling it vertically.

10. FIX TRANSMISSION OIL STRAINER

(a) Remove the bolt and oil strainer.

(b) Remove the O-ring from the oil strainer.
11. REMOVE HV MOTOR ASSEMBLY

(a) Place the motor on wooden blocks or equivalent.
12. REMOVE NO. 3 ENGINE MOUNTING BRACKET

(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 wiring harness connector (gray).
NOTE: Do not pull on the connector any more than necessary.

(b) Remove the connector and motor revolution sensor wiring harness connector (gray).
14. REMOVE MOTOR STATOR WIRING HARNESS CONNECTOR

(a) Remove the bolt and pull out the motor stator wiring harness connector (black).
NOTE: Do not pull on the sensor connector any more than necessary.

(b) Disconnect the connector and the motor stator wiring harness connector (black).
15. REMOVE SHIFT CONTROL ACTUATOR ASSEMBLY

(a) Remove the 3 bolts and shift control actuator.
16. REMOVE PARKING COVER

(a) Remove the 6 bolts and parking cover.
17. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY

(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 parking shaft cover.
20. REMOVE TRANSMISSION OIL PUMP COVER SUB-ASSEMBLY

(a) Remove the oil pump cover plug and O-ring.

(b) Remove the 5 bolts and oil pump cover.

(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 RACE

(a) Using SST, tap out the differential case tapered roller bearing LH outer race and shim.
SST: 09308-00010
23. REMOVE HYBRID TRANSAXLE OIL SEAL LH

(a) Place the motor on wooden blocks or equivalent.
NOTE: Make sure that the parking lock rod does not contact the wooden blocks.

(b) Using SST, tap out the oil seal.
SST: 09308-00010
24. REMOVE TRANSAXLE HOUSING AND CASE WITH HEAD STRAIGHT SCREW PLUG

(a) Remove the 2 set plugs and gasket.
(b) Using a 10 mm hexagon wrench, remove the screw plugs.
25. FIX HYBRID VEHICLE GENERATOR ASSEMBLY

(a) Place the generator on wooden blocks or equivalent.
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 wiring harness connector.
NOTE: Do not pull on the sensor connector any more than necessary.

(b) Disconnect the connector and the HV generator side generator revolution sensor wiring harness connector.

29. REMOVE TRANSAXLE HOUSING TUBE CONNECTOR
30. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY TYPE T OIL SEAL

(a) Using SST, remove the oil seal.
SST: 09612-30012
31. REMOVE HYBRID TRANSAXLE OIL SEAL RH

(a) Using SST, tap out the oil seal.
SST: 09308-00010
32. REMOVE DIFFERENTIAL CASE RH TAPERED ROLLER BEARING RACE

(a) Using SST, tap out the differential case tapered roller bearing LH outer race.
SST: 09308-00010
33. REMOVE TRANSAXLE HOUSING AND CASE WITH HEAD STRAIGHT SCREW PLUG

(a) Remove the set plug and gasket.
(b) Using a 6 mm socket wrench, remove the screw plug.