HYBRID VEHICLE TRANSAXLE REMOVAL

PROCEDURE


  1. REMOVE SERVICE PLUG GRIP

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  2. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  3. REMOVE FRONT WHEELS

  4. REMOVE ENGINE UNDER COVER LH

  5. REMOVE ENGINE UNDER COVER RH

  6. DRAIN COOLANT (for Engine)

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  7. DRAIN COOLANT (for Inverter)

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  8. DRAIN HYBRID TRANSAXLE FLUID

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  9. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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  10. REMOVE FRONT NO. 1 VENTILATOR SEAL (for LHD)

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  11. REMOVE FRONT NO. 1 VENTILATOR SEAL (for RHD)

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  12. REMOVE FRONT AIR SHUTTER SEAL RH (for LHD)

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  13. REMOVE FRONT AIR SHUTTER SEAL RH (for RHD)

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  14. REMOVE INNER COWL TOP TO COWL BRACE (for LHD)

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  15. REMOVE INNER COWL TOP TO COWL BRACE (for RHD)

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  16. REMOVE OUTER COWL TOP PANEL (for LHD)

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  17. REMOVE OUTER COWL TOP PANEL (for RHD)

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  18. REMOVE INVERTER WITH CONVERTER ASSEMBLY

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  19. REMOVE INVERTER BRACKET ASSEMBLY

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  20. REMOVE REAR CONSOLE BOX ASSEMBLY

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  21. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

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  22. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A01UZSQE02
      Text in Illustration
      *1 No. 1 Transmission Control Cable Clamp
      *2 No. 2 Transmission Control Cable Clamp

      Remove the nut and disconnect the transmission control cable assembly from the transmission control shaft lever.

      Note

      To prevent damage to the transmission control cable assembly and the shift lever assembly, disconnect the shift lever side of the transmission control cable assembly before disconnecting the transaxle side.

    2. Remove the clip and separate the transmission control cable assembly from the transmission control cable bracket.

    3. Separate the transmission control cable assembly from the No. 1 transmission control cable clamp and the No. 2 transmission control cable clamp.

  23. SEPARATE WIRE HARNESS


    1. A01UXSE

      Disengage the 4 clamps and separate the No. 2 engine wire from the hybrid vehicle transaxle assembly.

    2. Remove the 3 bolts, disconnect the 4 connectors, disengage the 7 clamps and separate the wire harness from the hybrid vehicle transaxle assembly.

      A01V02E

  24. REMOVE COLUMN HOLE COVER SILENCER SHEET

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  25. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY

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  26. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

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  27. REMOVE FRONT FLOOR CENTER BRACE

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  28. REMOVE FRONT EXHAUST PIPE ASSEMBLY

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  29. REMOVE FRONT DRIVE SHAFT ASSEMBLY

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  30. REMOVE DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY


    1. A01UYF7

      Remove the bolt, nut and the drive shaft heat insulator sub-assembly from the engine assembly and the drive shaft heat insulator bracket.

  31. REMOVE DRIVE SHAFT HEAT INSULATOR BRACKET


    1. A01UZTZ

      Disengage the clamp and separate the wire harness from the drive shaft heat insulator bracket.

    2. Remove the 2 bolts and the drive shaft heat insulator bracket from the engine assembly.

  32. REMOVE STARTER HOLE INSULATOR


    1. A01V149

      Remove the 2 bolts and the starter hole insulator from the engine assembly.

  33. REMOVE FLYWHEEL HOUSING SIDE COVER


    1. A01V26M

      Disengage the claw and remove the flywheel housing side cover from the engine assembly.

  34. SUPPORT ENGINE ASSEMBLY


    1. A01UY0G

      Place the wooden blocks or plate lift attachments in the positions shown in the illustration and set an engine lifter underneath the engine assembly.

      Text in Illustration
      A01UZS9 Attachment Placement Positions

      Note


      • Place the wooden blocks or plate lift attachments so that the engine with transaxle is level.

      • As the engine with transaxle is very heavy, be sure to support it securely.

      • To prevent deformation of the oil pan, never set any attachments against the oil pan of the engine.

  35. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

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  36. REMOVE NO. 2 ENGINE MOVING CONTROL ROD


    1. A01V0G5

      Remove the 4 bolts and the No. 2 engine moving control rod from the hybrid vehicle transaxle assembly.

  37. SUPPORT HYBRID VEHICLE TRANSAXLE ASSEMBLY


    1. Support the hybrid vehicle transaxle assembly with a transmission jack.

  38. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET


    1. A01UZNZ

      Remove the through bolt, nut and separate the transverse engine engine mounting bracket from the transverse engine engine mounting insulator.

      Tech Tips

      Turn the through bolt while holding the nut.

    2. A01UZ9U

      Remove the 4 bolts and the transverse engine engine mounting bracket from the hybrid vehicle transaxle assembly.

  39. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY


    1. A01UZYKE03
      Text in Illustration
      *1 Wire Harness Clamp Bracket
      *2 No. 1 Transmission Control Cable Clamp

      Remove the 3 bolts, 2 wire harness clamp brackets and the No. 1 transmission control cable clamp from the hybrid vehicle transaxle assembly.

    2. Operate the engine lifter and transmission jack, and slowly tilt the engine assembly with hybrid vehicle transaxle assembly.

      Note


      • Do not allow the engine and the transaxle to interfere with the vehicle body.

      • Do not tilt the engine more than necessary.

      • Do not allow wire harnesses and hoses to be pulled taut.

    3. A01V1L1

      Remove the 6 bolts and the hybrid vehicle transaxle assembly from the engine assembly.

      Note


      • To avoid damage to the knock pins, do not pry between the transaxle and the engine.

      • To prevent the splines of the damper from becoming misaligned, do not allow the transaxle to hit the damper during transaxle removal and installation.

  40. REMOVE MOTOR COOLING PIPE ASSEMBLY


    1. A01UY21

      Remove the bolt and the oil cooler tube clamp from the transmission control cable bracket.

    2. A01UZKSE03
      Text in Illustration
      *1 Flare Nut
      *2 Union
      *3 Union Bolt

      Using a union nut wrench 17 mm, disconnect the flare nut of the motor cooling pipe assembly from the union.

      Tech Tips

      Turn the flare nut while holding the union.

    3. Remove the union bolt, gasket and the motor cooling pipe assembly from the hybrid vehicle transaxle assembly.

    4. A01UYQ9

      Remove the union and O-ring from the hybrid vehicle transaxle assembly.

  41. REMOVE MOTOR CABLE

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  42. REMOVE TRANSMISSION CONTROL CABLE BRACKET


    1. A01V1BJ

      Remove the 2 bolts and the transmission control cable bracket from the hybrid vehicle transaxle assembly.

  43. REMOVE TRANSMISSION CONTROL SHAFT LEVER


    1. A01V15I

      Remove the nut, washer and the transmission control shaft lever from the shift lever position sensor.

  44. REMOVE SHIFT LEVER POSITION SENSOR

    Tech Tips

    Perform this procedure only when replacement of the automatic transmission case cover is necessary.


    1. A01UYM8E03
      Text in Illustration
      *1 Lock Plate

      Using a screwdriver, pry the tabs of the lock plate.

    2. A01UZS1E03
      Text in Illustration
      *1 Lock Nut
      *2 Lock Plate

      Remove the lock nut and lock plate from the shift lever position sensor.

    3. A01V1S0

      Remove the 2 bolts and pull out the shift lever position sensor from the hybrid vehicle transaxle assembly.

  45. REMOVE AUTOMATIC TRANSMISSION CASE COVER

    Tech Tips

    Perform this procedure only when replacement of the automatic transmission case cover is necessary.


    1. A01V10C

      Remove the 2 bolts and the automatic transmission case cover from the hybrid vehicle transaxle assembly.

  46. REMOVE MOTOR CABLE BRACKET


    1. A01UZQ2

      Remove the bolt and the motor cable bracket from the transmission control cable support.

  47. REMOVE TRANSMISSION CONTROL CABLE SUPPORT


    1. A01V27KE02
      Text in Illustration
      *1 Transmission Control Cable Support
      *2 No. 2 Transmission Control Cable Clamp

      Remove the 3 bolts and the transmission control cable support and the No. 2 transmission control cable clamp from the hybrid vehicle transaxle assembly.

  48. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A01UZH0

      Remove the bolt and the wire harness clamp bracket from the hybrid vehicle transaxle assembly.

  49. REMOVE TRANSAXLE HSG AND CASE WITH HEAD STRAIGHT SCREW PLUG


    1. A01UZO7

      Remove the transaxle HSG and case with head straight screw plug and gasket from the hybrid vehicle transaxle assembly.