HYBRID TRANSAXLE OIL SEAL REPLACEMENT

Tech Tips


  • Use the same procedure for the RH side and LH side.

  • The procedure listed below is for the LH side.


  1. REMOVE FRONT WHEEL

  2. REMOVE REAR ENGINE UNDER COVER LH

  3. REMOVE REAR ENGINE UNDER COVER RH

  4. REMOVE NO. 1 ENGINE UNDER COVER

  5. DRAIN HYBRID TRANSAXLE FLUID


    1. A003XN9E01
      Text in Illustration
      *1 Filler Plug
      *2 Drain Plug

      Using a 10 mm hexagon socket wrench, remove the filler plug and gasket.

    2. Using a 10 mm hexagon socket wrench, remove the drain plug and gasket.

    3. Using a 10 mm hexagon socket wrench, install the drain plug and a new gasket.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

  6. REMOVE FRONT AXLE SHAFT NUT


    1. A003WYUE01

      Using SST and a hammer, release the staked part of the front axle shaft nut.

      SST
      09930-00010

      Note

      Loosen the staked part of the nut completely, otherwise the threads of the drive shaft may be damaged.

    2. While applying the brakes, remove the front axle shaft nut.

  7. SEPARATE TIE ROD END SUB-ASSEMBLY


    1. Remove the clip and nut.

    2. A003YRZE03

      Install SST to the tie rod end.

      SST
      09960-20010   ( 09961-02060 )

      Note

      Make sure that the upper end of the tie rod end and SST are aligned.

    3. Secure SST using a string.

      Note

      Be sure to tighten the string firmly to secure SST to the steering knuckle to prevent SST from falling off.

    4. Using SST, separate the tie rod end from the steering knuckle.

      A003V3NE01
      Text in Illustration
      *1 Center Nut - -
      *a String *b Grease Application Area
      *c Place the wrench here. - -
      SST
      09960-20010   ( 09961-02010 )

      CAUTION:

      Apply grease to the bolt threads and the tip of SST.

      Note


      • Install SST with the center nut so that A and B shown in the illustration are parallel. Otherwise, the dust cover may be damaged.

      • Be sure to place the wrench on the part indicated in the illustration.

      • Do not damage the front disc brake dust cover.

      • Do not damage the ball joint dust cover.

      • Do not damage the steering knuckle.

  8. SEPARATE FRONT SPEED SENSOR


    1. A003YDN

      Remove the bolt and clamp, and separate the front speed sensor and front flexible hose from the front shock absorber with coil spring.

      Note

      Be sure to separate the front speed sensor from the front shock absorber with coil spring completely.

  9. SEPARATE FRONT FLEXIBLE HOSE


    1. A003XOM

      Remove the bolt and separate the front flexible hose from the steering knuckle.

  10. SEPARATE FRONT STABILIZER LINK ASSEMBLY


    1. A003YJM

      Remove the nut and separate the front stabilizer link assembly from the front shock absorber with coil spring.

      Tech Tips

      If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud bolt.

  11. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY


    1. A003Z94

      Remove the bolt and 2 nuts, and separate the front lower No. 1 suspension arm sub-assembly from the front lower ball joint assembly.

  12. SEPARATE FRONT DRIVE SHAFT ASSEMBLY


    1. A003XW4E02
      Text in Illustration
      *a Matchmark

      Put matchmarks on the front drive shaft assembly and front axle hub sub-assembly.

    2. Using a plastic hammer, separate the front drive shaft assembly from the front axle assembly. If it is difficult to separate, tap the end of the front drive shaft assembly using a brass bar and a hammer.

      Note

      Be careful not to damage the drive shaft boot.

  13. REMOVE FRONT DRIVE SHAFT ASSEMBLY


    1. A003XQ5E01

      Using SST, remove the front drive shaft assembly.

      SST
      09520-00031
      09520-01010

      Note


      • Do not damage the transaxle case oil seal.

      • Do not damage the inboard joint boot.

      • Do not drop the front drive shaft assembly.

  14. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING


    1. A003ZQG

      Using a screwdriver, remove the front drive shaft hole snap ring.

  15. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY TYPE T OIL SEAL


    1. A003WHRE04
      Text in Illustration
      *a LH Side
      *b RH Side

      Using SST, remove the 2 oil seals.

      SST
      09308-00010

  16. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY TYPE T OIL SEAL


    1. Install a new LH side oil seal.


      1. A003XRRE01

        Using SST and a hammer, tap in a new oil seal.

        SST
        09316-10010
        09950-70010   ( 09951-07150 )
        Oil seal installation depth
        -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

      2. Coat the lip of the oil seal with MP grease.

    2. Install a new RH side oil seal.


      1. A003WTRE01

        Using SST and a hammer, tap in a new oil seal.

        SST
        09726-36010
        09950-70010   ( 09951-07150 )
        Oil seal installation depth
        -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

      2. Coat the lip of the oil seal with MP grease.

  17. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING


    1. Install a new front drive shaft hole snap ring to the front drive inboard joint assembly.

      Note

      Face the end gap of the front drive inboard joint hole snap ring downward.

  18. INSTALL FRONT DRIVE SHAFT ASSEMBLY


    1. A003YU0

      Align the inboard joint splines, and using a brass bar and a hammer, install the front drive shaft assembly.

      Note


      • Face the end gap of the front drive shaft hole snap ring downward.

      • Do not damage the transaxle case oil seal.

      • Do not damage the inboard joint boot.

      • Make sure to center the front drive shaft assembly during installation to prevent damage to the front drive shaft hole snap ring.

      Tech Tips

      Confirm whether the drive shaft is securely driven in by checking the reaction force and sound.

    2. A003Y2VE02
      Text in Illustration
      *a Matchmark

      Align the matchmarks and install the front drive shaft assembly to the front axle hub sub-assembly.

  19. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY


    1. Install the front lower No. 1 suspension arm sub-assembly to the front lower ball joint assembly with the bolt and 2 nuts.

      Torque:
      89 N*m  { 908 kgf*cm, 66 ft.*lbf }

  20. INSTALL FRONT STABILIZER LINK ASSEMBLY


    1. Install the front stabilizer link assembly to the front shock absorber with coil spring with the nut.

      Torque:
      74 N*m  { 755 kgf*cm, 55 ft.*lbf }

      Tech Tips

      If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud bolt.

  21. INSTALL FRONT FLEXIBLE HOSE


    1. Install the front flexible hose to the steering knuckle with the bolt.

      Torque:
      19 N*m  { 192 kgf*cm, 14 ft.*lbf }

  22. INSTALL FRONT SPEED SENSOR


    1. Install the front speed sensor and front flexible hose to the front shock absorber with coil spring with the bolt and clamp.

      Torque:
      19 N*m  { 192 kgf*cm, 14 ft.*lbf }

      Note

      Do not twist the front speed sensor when installing it.

      Tech Tips

      Install the front flexible hose first and then the speed sensor harness bracket.

  23. CONNECT TIE ROD END SUB-ASSEMBLY


    1. A003Z1W

      Connect the tie rod end sub-assembly LH to the steering knuckle with the nut.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

      Note

      Further tighten the nut up to 60° if the holes for the clip are not aligned.

    2. Install a new clip.

  24. INSTALL FRONT AXLE SHAFT NUT


    1. Clean the threaded parts on the front drive shaft assembly and a new front axle shaft nut using a non-residue solvent.

      Tech Tips


      • Be sure to perform this work even when using a new drive shaft.

      • Keep the threaded parts free of oil and foreign matter.

    2. A003ZRD

      Using a socket wrench (30 mm), install the axle shaft nut.

      Torque:
      216 N*m  { 2203 kgf*cm, 159 ft.*lbf }

    3. Using a chisel and hammer, stake the front axle shaft nut.

  25. ADD HYBRID TRANSAXLE FLUID


    1. A003VF8E01
      Text in Illustration
      *1 Filler Plug
      *2 Filler Nozzle

      Add transaxle fluid until the fluid level is between 0 to 10 mm (0 to 0.394 in.) from the bottom lip of the filler plug opening.

      Note


      • Stop the vehicle on a level surface.

      • Use Toyota Genuine ATF WS.

      • Be sure to fully insert the filler nozzle into the filler plug opening.

      • Be sure to add fluid slowly. If fluid is added quickly, the fluid may hit internal parts and bounce back, resulting in fluid coming out of the filler plug opening.

      • Be sure to directly check that the transaxle fluid level is within the specified range.

      • Insufficient or excessive amounts of transaxle fluid may damage the hybrid transaxle.

      Reference
      3.4 liters (3.6 US qts, 3.0 lmp.qts)

    2. After adding fluid, leave it for 30 seconds so that the fluid surface can become still again, and then check that the fluid level is between 0 to 10 mm (0 to 0.394 in.) from the bottom lip of the filler plug opening. (If the fluid level is too low, return to the Add Hybrid Transaxle Fluid procedure.)

      Note

      After adding fluid, make sure to check the fluid level.

  26. INSPECT HYBRID TRANSAXLE FLUID


    1. A003VDTE01
      Text in Illustration
      *1 Filler Plug

      Using a 10 mm hexagon socket wrench, remove the filler plug and gasket.

    2. Check that the fluid level is between 0 to 10 mm (0 to 0.394 in.) from the bottom lip of the filler plug opening. (If the fluid level is too low, return to the Add Hybrid Transaxle Fluid procedure.)

      Note


      • Stop the vehicle on a level surface.

      • Be sure to directly check that the transaxle fluid level is within the specified range.

      • Insufficient or excessive amounts of transaxle fluid may damage the hybrid transaxle.

      • If the fluid was replaced or fluid was added, make sure to recheck the fluid level after driving the vehicle.

    3. Check for leaks if the quantity of transaxle fluid is low.

    4. Using a 10 mm hexagon socket wrench, install the filler plug with a new gasket.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

  27. INSPECT FOR TRANSAXLE FLUID LEAK

  28. INSTALL FRONT WHEEL (for 2ZR-FXE)

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }

  29. INSTALL FRONT WHEEL (for 5ZR-FXE)

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }

  30. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  31. INSTALL NO. 1 ENGINE UNDER COVER

  32. INSTALL REAR ENGINE UNDER COVER LH

  33. INSTALL REAR ENGINE UNDER COVER RH

  34. INSPECT SPEED SENSOR SIGNAL

    Click here