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.

    A01JC76E01
    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. A01JAVPE01

      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. A01JBQU

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

    2. A01J9KJ

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

    3. A01JBDJ

      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. A01J9L1

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

    2. A01J8L0

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

    3. A01J8DE

      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. A01JCHA

      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. A01JDBW

      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. A01JA1D

      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. A01JCWY

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

    2. A01JC6L

      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. A01JBT2E01
      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. A01J9CK

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

  8. REMOVE OIL PUMP DRIVE SHAFT


    1. A01JD3B

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

  9. SECURE HYBRID VEHICLE TRANSAXLE ASSEMBLY


    1. A01JBISE01
      Text in Illustration
      *1 Wooden Block
      *2 Resolver Sensor Connector
      *a Installation area of the Transmission Oil Pump Cover Sub-assembly
      A01JB8Y 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. A01JBQS

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

  11. REMOVE DRAIN PLUG


    1. A01JBL0

      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. A01JCEE

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

    2. A01JAF7

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

    3. A01J9TRE01
      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. A01JAEB

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

    2. A01JB6BE01
      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.

      A01J90EE01
      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. A01JAGX

      Remove the 8 bolts from the hybrid vehicle generator assembly.

    3. A01J9VS

      Remove the 8 bolts from the hybrid vehicle generator assembly.

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

    5. A01JBR8

      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. A01JD1X

      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 (for RH Side)


    1. A01JAA4E01

      Using SST and a hammer, remove the hybrid vehicle transaxle assembly type T oil seal 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. A01JCNU

      Using brass bar and a hammer, remove the tapered roller bearing (RH side outer race) and 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. A01JCNPE01
      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. A01JCD2

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

  20. REMOVE PARKING LOCK PAWL


    1. A01JA2S

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

  21. REMOVE PAWL STOPPER PLATE


    1. A01J9EK

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

  22. REMOVE TORSION SPRING


    1. A01J98P

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

  23. REMOVE PARKING LOCK SLEEVE


    1. A01JAQ6

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

  24. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY


    1. A01JCQM

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

  25. REMOVE RETAINER SPRING


    1. A01JCUW

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

  26. REMOVE NO. 1 PARKING LOCK SHAFT


    1. A01J9NL

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

    2. A01J8Z8

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

    3. A01JCKI

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

  27. REMOVE PARKING LOCK ROD SUB-ASSEMBLY


    1. A01J8RNE01
      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. A01JBGO

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

  28. REMOVE NO. 1 TRANSMISSION MAGNET


    1. A01JA2P

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

  29. REMOVE INPUT SHAFT ASSEMBLY


    1. A01JCSA

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

  30. REMOVE PLANETARY SUN GEAR


    1. A01J9C4E01
      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. A01JBPJE01
      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. A01JBII

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

  33. REMOVE COUNTER DRIVEN GEAR SUB-ASSEMBLY


    1. A01J9UM

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

  34. REMOVE COUNTER DRIVE GEAR SUB-ASSEMBLY


    1. A01JBEL

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

  35. REMOVE NO. 1 REAR PLANETARY GEAR ASSEMBLY


    1. A01JAIH

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

  36. INSPECT NO. 1 REAR PLANETARY GEAR ASSEMBLY


    1. A01J8QN

      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. A01J9MI

      Using a snap ring expander, remove the shaft snap ring from the hybrid vehicle motor assembly.

    2. A01JAJO

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

  38. REMOVE TRANSMISSION OIL STRAINER


    1. A01J953

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

    2. A01JB1L

      Remove the O-ring from the transmission oil strainer

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


    1. A01JACCE01

      Using SST and a hammer, remove the hybrid vehicle transaxle assembly type T oil seal 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. A01JBZ8

      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. A01J9SYE01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, remove the shaft 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


    1. Remove tapered roller bearing (LH side):


      1. A01JCPQE01
        Text in Illustration
        *a Hold
        *b Turn

        Using SST, remove the tapered roller bearing 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 )

    2. Remove tapered roller bearing (RH side):


      1. A01J96NE01
        Text in Illustration
        *a Hold
        *b Turn

        Using SST, remove the tapered roller bearing 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 RADIAL BALL BEARING


    1. Remove radial ball bearing (LH side):


      1. A01J9LEE01
        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 )

    2. Remove radial ball bearing (RH side):


      1. A01JC9NE01
        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 )

  44. REMOVE STRAIGHT PIN


    1. A01J9P3

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