Reassembly

HYBRID TRANSMISSION / TRANSAXLE: HYBRID VEHICLE TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY

1. INSTALL TRANSAXLE HOUSING AND CASE WITH HEAD STRAIGHT SCREW PLUG

(a) Install a new gasket and the set plug.
Torque: 39 Nm (400 kgf-cm, 29 ft-lbf)
(b) Apply liquid sealant 1344 to the first 2 to 3 threads from the end of the screw plug.
NOTE: Clean and degrease the screw and screw hole.

(c) Using a 6 mm socket hexagon wrench, install the screw plug.
Torque: 13 Nm (130 kgf-cm, 9 ft-lbf)
2. INSTALL TRANSAXLE HOUSING AND CASE WITH HEAD STRAIGHT SCREW PLUG

(a) Install a new gasket and the set plug.
Torque: 39 Nm (400 kgf-cm, 29 ft-lbf)
HINT: Tighten the set plug after adding transaxle oil.

(b) Apply liquid sealant 1324 to the first 2 to 3 threads from the end of the screw plug.
NOTE: Clean and degrease the screw and screw hole.

(c) Using a 10 mm socket hexagon wrench, install the screw plug.
Torque: 55 Nm (561 kgf-cm, 41 ft-lbf)
3. INSTALL HYBRID TRANSAXLE OIL SEAL RH

(a) Using SST, tap in a new oil seal.
Oil seal depth:
2.7 +-0.5 mm (0.106 +-0.020 in.)
(b) Coat the lip of the oil seal with No. 2 MP grease.
SST: 09350-32014
09351-32130
09351-32150
SST: 09950-70010
09951-07100
4. INSTALL HYBRID TRANSAXLE TYPE T 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 in the oil seal.
Standard depth:
2.7 +-0.5 mm (0.106 +-0.020 in.)
(c) Coat the lip of the oil seal with MP grease.
SST: 09350-32014
09351-32130
09351-32150
SST: 09950-70010
09951-07100
5. ADJUST PRELOAD
(a) Adjust the differential case preload.

(1) Place the motor on wooden blocks or equivalent.
NOTICE:
- Place the motor horizontally.
- Excessive force should not be applied to the cable.

(2) Using SST, tap in the differential case tapered roller bearing LH outer race and shim to the motor.
SST: 09950-60020
09951-00680
SST: 09950-70010
09951-07100
NOTE: Replace the shim and outer race with new ones if they are deformed or damaged.

(3) Using SST, tap in the differential case tapered roller bearing RH outer race to the generator.
SST: 09950-60020
09951-00680
SST: 09950-70010
09951-07100
NOTE: Replace the outer race with a new one if it is deformed or damaged.

(4) Apply ATF WS to the sliding surfaces of the differential case tapered roller bearing and install the bearing to the motor.

(5) Using an engine sling device and chain block, install the motor to the generator.
HINT:
- Engine hanger: 12281-67070, S1228-11781
- Bolt: 91642-81045, 91642-81265
- Nut: 90178-10001, 90179-12147

(6) Tighten the 13 bolts in the positions shown in the illustration.
Torque: 25 Nm (250 kgf-cm, 18 ft-lbf)

(7) Using SST, rotate the differential case in both directions to stabilize the bearings.
SST: 09564-32011

(8) Using SST, measure the differential preload of the differential case and rotation torque.
SST: 09564-32011
Standard preload (Starting torque):
0.98 to 1.57 N*m (9.99 to 16.01 kgf*cm, 8.67 to 13.90 in.*lbf) for new bearing
0.49 to 0.78 N*m (5.00 to 7.95 kgf*cm, 4.34 to 6.90 in.*lbf) for reused bearing
Standard preload (Turning torque):
0.61 to 1.35 N*m (20 rpm) at 20°C (6.2 to 13.77 kgf*cm, 5.4 to 11.95 in.*lbf)
HINT:
- If the preload is not within the specified range, replace the shim with a new one to adjust the preload.
- Remove the motor side tapered roller bearing outer race and shim when replacing the shim.
- Replace the shim and outer race with new ones if they are deformed or damaged.
- As the shim thickness is increased 0.02 mm (0.0008 in.), the preload increases approximately 0.23 N*m (2.4 kgf*cm, 2.04 in.*lbf) accordingly.
Standard shim thickness:

(9) Using an engine sling device and chain block, remove the 13 bolts and generator.
6. INSTALL DIFFERENTIAL DRIVE PINION

(a) Install the differential drive pinion.
NOTICE:
- Insert the differential drive pinion vertically.
- Ensure that the differential drive pinion is fully inserted.

7. SELECT SHIM
(a) Select the input shaft shim.

(1) Install the No. 1 thrust bearing race.
(2) Apply ATF WS to the sliding surfaces of the thrust needle roller bearing and install the flange bearing.
(3) Install the thrust bearing race.

(4) Install the drive sprocket.

(5) Install the input shaft.

(6) Install the No. 1 thrust bearing race.
(7) Apply ATF WS to the sliding surfaces of the thrust needle roller bearing and install the flange bearing.
(8) Install the thrust bearing race.

(9) Install the planetary ring gear.

(10) Install the planetary ring gear flange.

(11) Using a straightedge and vernier caliper, measure dimension A as shown in the illustration.
Standard value:
Dimension A = Measured value - width of straightedge used
- Measure dimension A without the shim installed.
- Take the measurement 3 times each in 3 different locations and use the average of the measurements taken.
- Two people are required for this step because it is difficult to keep the straightedge level. One person should hold the straightedge, and the other person measure dimension A.

(12) Using a straightedge and vernier caliper, measure dimension B as shown in the illustration.
Standard value:
Dimension B = Measured value - thickness of straightedge used
NOTE: Dimension B is greater than dimension A.

(13) Select a shim.
Standard value:
Select shim = (Dimension B - Dimension A) - 0.1 mm (0.0039 in.) to 0.4 mm (0.0157 in.)
NOTE: Subtract 0.1 mm (0.004 in.) to 0.4 mm (0.016 in.) from the difference of Dimension B and Dimension A and select a shim on the basis of the resulting value. This is done because clearance 0.1 mm (0.004 in.) to 0.4 mm (0.016 in.) with the input shaft is required.

Standard shim thickness:

(b) Select a counter drive gear shim.

(1) Install the counter drive gear.
NOTICE:
- Insert the counter drive gear vertically.
- Ensure that the counter drive gear is fully inserted.

(2) Using a straightedge and vernier caliper, measure dimension A as shown in the illustration.
Standard value:
Dimension A = Measured value - width of straightedge used
- Measure dimension A without the shim installed.
- Take the measurement 3 times each in 3 different locations and use the average of the measurements taken.
- Two people are required for this step because it is difficult to keep the straightedge level. One person should hold the straightedge, and the other person measure dimension A.
(3) Using a straightedge and vernier caliper, measure dimension B as shown in the illustration.
Standard value:
Dimension B = Measured value - thickness of straightedge used
NOTE: Dimension B is greater than dimension A.
(4) Select a shim.
Standard value:
Selected shim = (Dimension B - Dimension A) - 0 mm (0 in.) to 0.1 mm (0.004 in.)
NOTE: Subtract 0 mm (0 in.) to 0.1 mm (0.004 in.) from the difference of Dimension B and Dimension A and select a shim on the basis of the resulting value. This is done because clearance 0 mm (0 in.) to 0.1 mm (0.004 in.) with the counter drive gear is required.

Standard shim thickness:

8. INSTALL INPUT SHAFT ASSEMBLY

(a) Install the shim selected.

(b) Install the planetary ring gear flange.
(c) Install the thrust bearing race.
(d) Install the thrust needle roller bearing.
(1) Apply ATF WS to the sliding surfaces of the thrust needle roller bearing and install the flange.
(e) Install the thrust bearing race.

(f) Install the planetary ring gear.

(g) Install the input shaft.
9. INSTALL SPROCKET DRIVEN GEAR AND COUNTER DRIVE GEAR

(a) Install the counter drive gear shim selected.

(b) Install the counter drive gear and chain.
- Insert the counter drive gear vertically.
- Ensure that the counter drive gear is fully inserted.

10. INSTALL TRANSMISSION DRIVE SPROCKET SUB-ASSEMBLY

(a) Apply ATF WS auto fluid to the drive sprocket needle roller bearing and put the drive sprocket on the chain.
(b) Align the recesses of the planetary ring gear and the drive sprocket and install the drive sprocket with chain.
11. INSTALL NO. 2 THRUST BEARING RACE
(a) Install the thrust bearing race.

(b) Install the No. 1 drive sprocket thrust needle roller bearing.
(1) Apply ATF WS to the sliding surfaces of the thrust needle roller bearing and install the bearing.
(c) Install the No. 2 thrust bearing race.
12. INSTALL TRANSMISSION OIL STRAINER

(a) Apply ATF WS to a new O-ring and install the fluid strainer.

(b) Install the oil strainer with the bolt.
Torque: 7.9 Nm (81 kgf-cm, 70 in-lbf)
13. INSTALL HYBRID VEHICLE GENERATOR ASSEMBLY

(a) Apply seal packing in a continuous line of beads (diameter 1.5 mm, 0.059 in.) to the motor side.
Seal packing:
Toyota Genuine Seal Packing 1281,
Three Bond 1281 or equivalent
- Clean and degrease the installation surfaces.
- Install within 10 minutes of applying seal packing.

(b) Using an engine sling device and chain block, install the parking lock rod to the generator so that it is inserted into the cam guide sleeve.

NOTE: Rotate the input shaft in both directions so that the gears interlock if the generator cannot be easily installed.

(c) Apply adhesive to the first 2 to 3 threads of the bolt end.
Adhesive:
Toyota Genuine Adhesive 1344,
Three Bond 1344 or equivalent
NOTE: Clean and degrease the bolt and bolt holes.

(d) Install the 21 bolts as shown in the illustration.
Torque: 25 Nm (250 kgf-cm, 18 ft-lbf)
HINT:
- 13 bolts on the generator side
- 8 bolts on the motor side

14. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY TYPE T OIL SEAL

(a) Coat the lip of a new oil seal with MP grease.
NOTE: Ensure that no foreign objects adhere to the oil seal lip.

(b) Using SST, tap in oil seal.
Standard depth:
1 to 1.5 mm (0.039 to 0.059 in.)
NOTE: Ensure that the oil seal is fitted straight.

15. FIX HYBRID VEHICLE TRANSAXLE ASSEMBLY

(a) Set the hybrid transaxle as shown in the illustration.
16. INSTALL PARKING COVER

(a) Apply seal packing in a continuous line of beads (diameter 1.5 mm, 0.06 in.) as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1281,
Three Bond 1281 or equivalent
- Clean and degrease the installation surfaces.
- Install within 10 minutes of applying seal packing.

(b) Install the parking shaft cover with the 5 bolts.
Torque: 5.5 Nm (56 kgf-cm, 49 in-lbf)
17. INSTALL MOTOR WATER JACKET COVER

(a) Apply seal packing black in a continuous line of beads (diameter 1.5 mm, 0.06 in.) as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1281,
Three Bond 1281 or equivalent
- Clean and degrease the installation surfaces.
- Install within 10 minutes of applying seal packing.

(b) Apply adhesive to the first 2 to 3 threads of each of the 6 bolts. Install the motor water jacket cover with the 6 bolts.
Adhesive:
Toyota Genuine Adhesive 1344,
Three Bond 1344 or equivalent
Torque: 5.5 Nm (56 kgf-cm, 49 in-lbf)
NOTE: Clean and degrease the bolt and bolt holes.

18. INSTALL TRANSAXLE HOUSING TUBE CONNECTOR

(a) Apply adhesive to the first 2 to 3 threads of the bolt and install.
Adhesive:
Toyota Genuine Adhesive 1344,
Three Bond 1344 or equivalent
Torque: 15 Nm (155 kgf-cm, 11 ft-lbf)
NOTE: Clean and degrease the bolt and bolt holes.

(b) Install the drain plug using a new gasket.
Torque: 39 Nm (400 kgf-cm, 29 ft-lbf)
19. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY

(a) Install the manual detent spring and manual detent spring cover with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 86 in-lbf)
20. REMOVE PARKING COVER

(b) Install the parking cover with the 6 bolts.
Torque: 5.5 Nm (56 kgf-cm, 49 in-lbf)
21. INSTALL SHIFT CONTROL ACTUATOR ASSEMBLY

(a) Apply a small amount of genuine ATF WS to the O-ring.

(b) Install the shift control actuator with the 3 bolts.
Torque: 16 Nm (160 kgf-cm, 12 ft-lbf)
(c) Install the transmission case cover with the 3 bolts.
22. INSTALL OIL PUMP DRIVE SHAFT

(a) Apply ATF WS to the fluid pump drive shaft and install it.
23. INSTALL OIL PUMP DRIVEN ROTOR

(a) Apply ATF WS to the fluid pump driven rotor and install it.
24. INSTALL TRANSAXLE OIL PUMP DRIVE ROTOR

(a) Apply ATF WS to the transaxle fluid pump drive rotor and install it.
25. INSTALL TRANSMISSION OIL PUMP COVER SUB-ASSEMBLY

(a) Install a new O-ring.
NOTE: Ensure that the O-ring is not twisted.

(b) Apply adhesive to the first 2 to 3 threads of the bolt end.
Adhesive:
Toyota Genuine Adhesive 1344,
Three Bond 1344 or equivalent
NOTE: Clean and degrease the bolts and bolt holes.

(c) Install the oil pump cover with the 5 bolts.
Torque: 5.5 Nm (56 kgf-cm, 49 in-lbf)

(d) Install a new O-ring and fluid pump cover plug.
26. INSTALL MOTOR STATOR WIRING HARNESS CONNECTOR

(a) Apply ATF WS to the O-ring and install the motor stator wiring harness connectors (black) with the bolt.
Torque: 5.8 Nm (59 kgf-cm, 51 in-lbf)
27. INSTALL MOTOR REVOLUTION SENSOR WIRING HARNESS CONNECTOR

(a) Apply ATF WS to the O-ring and install the HV motor side motor revolution sensor wiring harness connectors (gray) with the bolt.
Torque: 5.8 Nm (59 kgf-cm, 51 in-lbf)
28. INSTALL GENERATOR MOTOR REVOLUTION SENSOR WIRING HARNESS CONNECTOR

(a) Apply ATF WS to the O-ring and install the HV generator side generator motor revolution sensor wiring harness connector with the bolt.
Torque: 5.8 Nm (59 kgf-cm, 51 in-lbf)
29. INSTALL GENERATOR CABLE

(a) Align the generator cables as shown in the illustration and connect them.
- Aligning the letters U, V and W, and connect the cable.
- Apply a small amount of ATF WS to the O-ring.

(b) Apply adhesive to the first 2 or 3 threads of bolts B and install the generator cable with the bolts.
Torque: 5.8 Nm (59 kgf-cm, 51 in-lbf)(bolt B)
Adhesive:
Toyota Genuine Adhesive 1344,
Three Bond 1344 or equivalent
NOTE: Clean and degrease the bolts and bolt holes.

(c) Install the generator cable with the 3 bolts (A).
Torque: 8.5 Nm (87 kgf-cm, 75 in-lbf)(bolt A)
30. INSTALL POWER CABLE COVER

(b) Apply adhesive to the first 2 or 3 threads of the 4 bolts and install the power cable cover.
Adhesive:
Toyota Genuine Adhesive 1344,
Three Bond 1344 or equivalent
Torque: 4.8 Nm (49 kgf-cm, 42 in-lbf)
NOTE: Clean and degrease the bolts and bolt holes.

(a) Apply adhesive to the first 2 or 3 threads of the 3 bolts and install the engine mounting bracket.
Adhesive:
Toyota Genuine Adhesive 1344,
Three Bond 1344 or Equivalent
Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)
NOTE: Clean and degrease the bolts and bolt holes.

32. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY