HYBRID VEHICLE TRANSAXLE UNIT DISASSEMBLY

Note


  • Do not use gloves, cloths or papers that produce lint or dust.

  • Cover the removed parts with plastic bags to prevent entry of foreign matter.

  • Do not remove the generator cable terminal, motor cable terminal, transaxle housing cover, rear transaxle case cover sub-assembly or resolver adjuster bolts.

    A0043VQE01
    Text in Illustration
    *1 Generator Cable Terminal *2 Motor Cable Terminal
    *3 Transaxle Housing Cover *4 Rear Transaxle Case Cover Sub-assembly
    *5 Resolver Adjuster Bolt - -

  1. INSPECT INPUT SHAFT END PLAY


    1. A0040FRE01

      Using a SST and dial indicator, measure the input shaft assembly end play.

      SST
      09951-01600
      Standard end play
      0.10 to 0.20 mm (0.00394 to 0.00787 in.)

      If the value is not as specified, replace the planetary sun gear snap ring with one of the correct thickness.

  2. REMOVE GENERATOR CABLE


    1. A00410L

      Remove the 3 bolts and slide the generator cable connector shell back.

    2. A00434S

      Disengage the 2 claws to remove the terminal cap from the hybrid vehicle transaxle assembly.

    3. A0043AV

      Remove the 3 bolts and generator cable from the hybrid vehicle transaxle assembly.

      Note

      Keep foreign matter, water, etc. away from the terminal cable and its installation section.

  3. REMOVE MOTOR CABLE


    1. A00429S

      Remove the 3 bolts and slide the motor cable connector shell back.

    2. A00426G

      Disengage the 2 claws to remove the terminal cap from the hybrid vehicle transaxle assembly.

    3. A0043OB

      Remove the 3 bolts and motor cable from the hybrid vehicle transaxle assembly.

      Note

      Keep foreign matter, water, etc. away from the terminal cable and its installation section.

  4. REMOVE SHIFT CONTROL ACTUATOR ASSEMBLY


    1. A0040QU

      Remove the 3 shift control actuator bolts and shift control actuator assembly from the hybrid vehicle transaxle assembly.

      Tech Tips


      • Please refer to Service Bulletin for details on the removal procedure of the shift control actuator bolt.

      • This actuator is a precision instrument. Do not strike it with a plastic hammer or the like during installation.

      • This actuator detects its own position when a battery is reinstalled. Thus it does not require initialization.

  5. REMOVE TRANSAXLE BREATHER PLUG


    1. A0043YB

      Remove the transaxle breather plug from the hybrid vehicle transaxle assembly.

      Note

      Be careful not to damage the transaxle breather plug.

  6. REMOVE WITH HEAD STRAIGHT SCREW PLUG


    1. A0040J1

      Using a 6 mm hexagon socket wrench, remove the 2 with head straight screw plugs from the hybrid vehicle transaxle assembly.

  7. REMOVE TRANSMISSION OIL PUMP COVER SUB-ASSEMBLY


    1. A0040ZT

      Remove the fluid pump cover plug and O-ring from the transmission oil pump cover sub-assembly.

    2. A0043TN

      Remove the 4 bolts and transmission oil pump cover sub-assembly from the hybrid vehicle transaxle assembly.

      Note

      Do not drop the transaxle oil pump drive rotor or transmission oil pump driven rotor.

    3. A004438E01
      Text in Illustration
      *1 Transaxle Oil Pump Drive Rotor
      *2 Transmission Oil Pump Driven Rotor

      Remove the transaxle oil pump drive rotor and transmission oil pump driven rotor from the hybrid vehicle transaxle assembly.

    4. A0041GK

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

  8. REMOVE OIL PUMP DRIVE SHAFT


    1. A0040MD

      Remove the oil pump drive shaft from the hybrid vehicle transaxle assembly.

  9. SECURE HYBRID VEHICLE TRANSAXLE ASSEMBLY


    1. A0042CCE01
      Text in Illustration
      *1 Wooden Block
      *2 Resolver Sensor Connector
      *a Installation area of the Transmission Oil Pump Cover Sub-assembly
      A0040ED Wooden Block Placement Position

      Place wooden blocks under the hybrid vehicle transaxle assembly.

      Note

      Do not place the wooden blocks under the installation area of the transmission oil pump cover sub-assembly or resolver sensor connector.

  10. REMOVE FILLER PLUG


    1. A00417M

      Using a 10 mm hexagon socket wrench, remove the filler plug and gasket from the hybrid vehicle transaxle assembly.

  11. REMOVE DRAIN PLUG


    1. A0041U2

      Using a 10 mm hexagon socket wrench, remove the drain plug and gasket from the hybrid vehicle transaxle assembly.

  12. REMOVE NO. 1 MOTOR WATER JACKET COVER ASSEMBLY


    1. A0043K0

      Using a 10 mm hexagon socket wrench, remove the drain plug and gasket from the No. 1 motor water jacket cover assembly.

    2. A0043IG

      Remove the 6 bolts from the No. 1 motor water jacket cover assembly.

    3. A0041FKE01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, remove the No. 1 motor water jacket cover assembly from the hybrid vehicle transaxle assembly.

      Note

      Be careful not to damage the hybrid vehicle transaxle assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  13. REMOVE NO. 2 MOTOR WATER JACKET COVER ASSEMBLY


    1. A00407L

      Remove the 6 bolts from the No. 2 motor water jacket cover assembly.

    2. A00417KE01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, remove the No. 2 motor water jacket cover assembly from the hybrid vehicle transaxle assembly.

      Note

      Be careful not to damage the hybrid vehicle transaxle assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  14. REMOVE HYBRID VEHICLE GENERATOR ASSEMBLY


    1. Install the No. 1 engine hanger and No. 2 engine hanger with the 2 bolts and washer as shown in the illustration.

      A0041RTE01
      Text in Illustration
      *1 No. 1 Engine Hanger *2 No. 2 Engine Hanger
      *3 Washer - -
      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      Part Name Part No.
      No. 1 Engine Hanger 12281-37050
      No. 2 Engine Hanger 12282-37040
      Bolt 91552-81050

      Tech Tips

      When installing the No. 1 engine hanger, use a washer with an appropriate thickness so that the No. 1 engine hanger will not interfere with the installation surface of the transaxle housing.

    2. A003ZZB

      Remove the 8 bolts from the hybrid vehicle generator assembly.

    3. A0043M4

      Remove the 8 bolts from the hybrid vehicle generator assembly.

    4. Remove the 2 bolts from the hybrid vehicle motor assembly.

    5. A0042DV

      While lifting the hybrid vehicle generator assembly with a chain, tap the areas shown in the illustration with a plastic hammer and separate the hybrid vehicle generator assembly from the hybrid vehicle motor assembly.

    6. While lifting the hybrid vehicle generator assembly with a chain, remove it from the hybrid vehicle motor assembly.

      Note


      • Lift the hybrid vehicle generator assembly straight up.

      • If the hybrid vehicle generator assembly is tilted, return it to the original position before removing.

    7. Remove the 2 bolts, washer, No. 1 engine hanger and No. 2 engine hanger from the hybrid vehicle generator assembly.

  15. REMOVE TRANSAXLE HOUSING OIL SEPARATOR


    1. A004390

      Remove the 2 bolts and transaxle housing oil separator from the hybrid vehicle generator assembly.

  16. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY TYPE T OIL SEAL (RH SIDE)


    1. A0044C2E01

      Using SST and a hammer, remove the hybrid vehicle transaxle assembly type T oil seal (RH side) from the hybrid vehicle generator assembly.

      SST
      09950-60010   ( 09951-00590 )
      09950-70010   ( 09951-07200 )

  17. REMOVE TAPERED ROLLER BEARING (RH SIDE OUTER RACE)


    1. A0043KT

      Using brass bar and a hammer, remove the tapered roller bearing (RH side outer race) and differential case RH shim from the hybrid vehicle generator assembly.

      Note

      Be careful not to damage the hybrid vehicle generator assembly.

  18. REMOVE INPUT SHAFT TYPE T OIL SEAL


    1. A0041E0E01
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the input shaft type T oil seal from the hybrid vehicle generator assembly.

      SST
      09310-36021

      Note


      • Be careful not to damage the hybrid vehicle generator assembly.

      • When removing the hybrid vehicle generator assembly, be sure to replace the input shaft type T oil seal.

  19. REMOVE COUNTER DRIVEN GEAR SHIM


    1. A00444V

      Remove the counter driven gear shim from the counter driven gear sub-assembly.

  20. REMOVE PARKING LOCK PAWL


    1. A0040FQ

      Remove the parking lock pawl and parking lock pawl shaft from the hybrid vehicle motor assembly.

  21. REMOVE PAWL STOPPER PLATE


    1. A0041OI

      Remove the 2 bolts and pawl stopper plate from the hybrid vehicle motor assembly.

  22. REMOVE TORSION SPRING


    1. A0040VY

      Remove the parking lock pawl shaft and torsion spring from the hybrid vehicle motor assembly.

  23. REMOVE PARKING LOCK SLEEVE


    1. A0040DX

      Remove the parking lock sleeve from the hybrid vehicle motor assembly.

  24. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY


    1. A00407X

      Remove the bolt and manual detent spring sub-assembly from the hybrid vehicle motor assembly.

  25. REMOVE RETAINER SPRING


    1. A0043LH

      Remove the retainer spring from the hybrid vehicle motor assembly and No. 1 parking lock shaft.

  26. REMOVE NO. 1 PARKING LOCK SHAFT


    1. A00437E

      Using a hammer and a screwdriver, cut off the spacer and remove it from the No. 1 parking lock shaft.

    2. A00431O

      Using a 5 mm pin punch and a hammer, drive out the slotted spring pin from the No. 1 parking lock shaft.

    3. A0042UC

      Remove the No. 1 parking lock shaft from the hybrid vehicle motor assembly.

  27. REMOVE PARKING LOCK ROD SUB-ASSEMBLY


    1. A0041RPE01
      Text in Illustration
      *1 No. 1 Parking Lock Lever Sub-assembly
      *2 Parking Lock Rod Sub-assembly

      Remove the No. 1 parking lock lever sub-assembly and parking lock rod sub-assembly from the hybrid vehicle motor assembly.

    2. A0040CO

      Remove the parking lock rod sub-assembly from the No. 1 parking lock lever sub-assembly.

  28. REMOVE NO. 1 TRANSMISSION MAGNET


    1. A00436F

      Remove the No. 1 transmission magnet from the hybrid vehicle motor assembly.

  29. REMOVE INPUT SHAFT ASSEMBLY


    1. A0043M1

      Remove the input shaft assembly from the counter drive gear sub-assembly.

  30. REMOVE PLANETARY SUN GEAR


    1. A00407TE01
      Text in Illustration
      *1 Planetary Sun Gear Snap Ring
      *2 Planetary Sun Gear

      Remove the planetary sun gear snap ring and planetary sun gear from the input shaft assembly.

  31. REMOVE THRUST NEEDLE ROLLER BEARING


    1. A0041W1E01
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing
      *3 No. 1 Thrust Bearing Race

      Remove the thrust bearing race, thrust needle roller bearing and No. 1 thrust bearing race from the input shaft assembly.

      Tech Tips

      The No. 1 thrust bearing race may be attached to the input shaft assembly.

  32. REMOVE DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A0042MC

      Remove the differential case sub-assembly from the hybrid vehicle motor assembly.

  33. REMOVE COUNTER DRIVEN GEAR SUB-ASSEMBLY


    1. A00418W

      Remove the counter driven gear sub-assembly from the hybrid vehicle motor assembly.

  34. REMOVE COUNTER DRIVE GEAR SUB-ASSEMBLY


    1. A004129

      Remove the counter drive gear sub-assembly from the No. 1 rear planetary gear assembly.

  35. REMOVE NO. 1 REAR PLANETARY GEAR ASSEMBLY


    1. A004024

      Remove the No. 1 rear planetary gear assembly from the rear planetary sun gear.

  36. INSPECT NO. 1 REAR PLANETARY GEAR ASSEMBLY


    1. A0040SW

      Using a feeler gauge, measure the clearance between the No. 1 rear planetary gear assembly and the pinion gear.

      Standard clearance
      0.11 to 0.91 mm (0.00433 to 0.0358 in.)

      If the value is not as specified, replace the No. 1 rear planetary gear assembly.

  37. REMOVE REAR PLANETARY SUN GEAR


    1. A00408D

      Using a snap ring expander, remove the rear planetary sun gear shaft snap ring from the hybrid vehicle motor assembly.

    2. A0043NK

      Remove the rear planetary sun gear from the hybrid vehicle motor assembly.

  38. REMOVE TRANSMISSION OIL STRAINER


    1. A0040DU

      Remove the bolt and transmission oil strainer from the hybrid vehicle motor assembly.

    2. A00449E

      Remove the O-ring from the transmission oil strainer

  39. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY TYPE T OIL SEAL (LH SIDE)


    1. A004234E01

      Using SST and a hammer, remove the hybrid vehicle transaxle assembly type T oil seal (LH side) from the hybrid vehicle motor assembly.

      SST
      09950-60010   ( 09951-00620 )
      09950-70010   ( 09951-07200 )

  40. REMOVE TAPERED ROLLER BEARING (LH SIDE OUTER RACE)


    1. A0042LL

      Using brass bar and a hammer, remove the tapered roller bearing (LH side outer race) from the hybrid vehicle motor assembly.

      Note

      Be careful not to damage the hybrid vehicle motor assembly.

  41. REMOVE SHIFT CONTROL ACTUATOR SEAL


    1. A00425JE01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, remove the shift control actuator seal from the hybrid vehicle motor assembly.

      Note

      Be careful not to damage the hybrid vehicle motor assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  42. REMOVE TAPERED ROLLER BEARING (RH SIDE INNER RACE)


    1. A0042DOE01
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the tapered roller bearing (RH side inner race) from the differential case sub-assembly.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00460 )

  43. REMOVE TAPERED ROLLER BEARING (LH SIDE INNER RACE)


    1. A0040ILE01
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the tapered roller bearing (LH side inner race) from the differential case sub-assembly.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00460 )

  44. REMOVE RADIAL BALL BEARING (LH SIDE)


    1. A0043O2E01
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the radial ball bearing (LH side) from the counter driven gear sub-assembly.

      SST
      09950-00020
      09950-00030
      09950-40011   ( 09957-04010 )
      09950-60010   ( 09951-00280 )

  45. REMOVE RADIAL BALL BEARING (RH SIDE)


    1. A0042GZE01
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the radial ball bearing (RH side) from the counter driven gear sub-assembly.

      SST
      09950-00020
      09950-00030
      09950-40011   ( 09957-04010 )
      09950-60010   ( 09951-00280 )

  46. REMOVE STRAIGHT PIN


    1. A0041NA

      Remove the 2 straight pins from the hybrid vehicle motor assembly.