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 power cable cover, generator cable, transaxle housing cover, rear transaxle case cover sub-assembly, rear planetary sun gear shaft snap ring or rear planetary sun gear.

  • The resolver is not adjustable. Do not remove the adjuster bolts.

    A01NIZVE01
    Text in Illustration
    *1 Power Cable Cover *2 Generator Cable
    *3 Transaxle Housing Cover *4 Rear Transaxle Case Cover Sub-assembly
    *5 Resolver Adjuster Bolt *6 Rear Planetary Sun Gear Shaft Snap Ring
    *7 Rear Planetary Sun Gear - -

  1. INSPECT INPUT SHAFT ASSEMBLY END PLAY


    1. A01NI4ZE01

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

      SST
      09951-01600
      Standard End Play
      0.1 to 0.2 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 INLET OIL COOLER TUBE SUB-ASSEMBLY


    1. A01NLNFE01
      Text in Illustration
      *1 Oil Cooler Tube Union
      *2 Inlet Oil Cooler Tube Sub-assembly
      *3 No. 2 Oil Cooler Tube Clamp

      Using a 17 mm union nut wrench, separate the inlet oil cooler tube sub-assembly from the oil cooler tube union.

      Note

      Turn the inlet oil cooler tube sub-assembly while holding the oil cooler tube union.

    2. Remove the bolt, No. 2 oil cooler tube clamp and inlet oil cooler tube sub-assembly from the No. 1 oil cooler tube clamp.

    3. A01NKUQ

      Remove the bolt and No. 1 oil cooler tube clamp from the hybrid vehicle transaxle assembly.

  3. REMOVE NO. 2 AUTOMATIC TRANSMISSION CASE COVER


    1. A01NJVZ

      Remove the 2 bolts, clip and No. 2 automatic transmission case cover from the hybrid vehicle transaxle assembly.

  4. REMOVE OIL COOLER TUBE UNION


    1. A01NMTD

      Remove the oil cooler tube union from the hybrid vehicle transaxle assembly.

    2. A01NJ2N

      Remove the O-ring from the oil cooler tube union.

  5. REMOVE SHIFT LEVER POSITION SENSOR


    1. A01NK5K

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

    2. A01NKSS

      Using a screwdriver, pry out the lock plate.

    3. A01NKNO

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

    4. A01NN2Y

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

  6. REMOVE TRANSAXLE BREATHER PLUG


    1. A01NLJ1E01

      Using SST, remove the transaxle breather plug from the hybrid vehicle transaxle assembly.

      SST
      09810-38140

      Note

      Be careful not to damage the transaxle breather plug.

  7. REMOVE TRANSMISSION OIL PUMP COVER SUB-ASSEMBLY


    1. A01NMWR

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

    2. A01NL2G

      Remove the 5 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 oil pump driven rotor.

    3. A01NIPYE01
      Text in Illustration
      *1 Transaxle Oil Pump Drive Rotor
      *2 Oil Pump Driven Rotor

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

    4. A01NKJ9

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

  8. REMOVE OIL PUMP DRIVE SHAFT


    1. A01NJH1

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

  9. SECURE HYBRID VEHICLE TRANSAXLE ASSEMBLY


    1. A01NK97E02
      Text in Illustration
      *a Wooden Block
      *b Resolver Sensor Connector
      *c Installation area of the transmission oil pump cover sub-assembly
      A01NKRA 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. A01NJTX

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

  11. REMOVE DRAIN PLUG


    1. A01NM3K

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

  12. REMOVE WITH HEAD STRAIGHT SCREW PLUG (for RH Side)


    1. A01NJA4

      Using a 10 mm hexagon socket wrench, remove the with head straight screw plug and gasket from the hybrid vehicle transaxle assembly.

  13. REMOVE WITH HEAD STRAIGHT SCREW PLUG (for Upper Side)


    1. A01NJD2

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

      Note

      Do not allow any remaining seal packing to enter the hybrid vehicle transaxle assembly.

  14. REMOVE NO. 2 MOTOR WATER JACKET COVER ASSEMBLY


    1. A01NJXE

      Using a 10 mm hexagon socket wrench, remove the drain plug and gasket from the No. 2 motor water jacket cover assembly.

    2. A01NK87

      Remove the 5 bolts and No. 2 motor water jacket cover assembly from the hybrid vehicle transaxle assembly.

  15. REMOVE NO. 1 MOTOR WATER JACKET COVER ASSEMBLY


    1. A01NMXN

      Remove the 8 bolts and No. 1 motor water jacket cover assembly from the hybrid vehicle transaxle assembly.

  16. REMOVE MOTOR WATER JACKET COVER ASSEMBLY


    1. A01NLA2

      Remove the 12 bolts and motor water jacket cover assembly from the hybrid vehicle transaxle assembly.

  17. 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.

      A01NLF5E01
      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. 2 engine hanger, use a washer with an appropriate thickness so that the No. 2 engine hanger will not interfere with the installation surface of the hybrid vehicle generator assembly.

    2. A01NN5C

      Remove the 9 bolts from the hybrid vehicle generator assembly.

    3. A01NIK2

      Remove the 7 bolts from the hybrid vehicle generator assembly.

    4. A01NN1N

      Remove the 3 bolts from the hybrid vehicle motor assembly.

    5. A01NLRU

      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.

  18. REMOVE TAPERED ROLLER BEARING (OUTER RACE) (for RH Side)


    1. A01NJ0HE01

      Using SST, remove the tapered roller bearing (outer race) and differential case RH shim from the hybrid vehicle generator assembly.

      SST
      09308-36010

      Note

      Be careful not to damage the hybrid vehicle generator assembly.

  19. REMOVE TAPERED ROLLER BEARING (OUTER RACE) (for RH Side)


    1. A01NIXHE01
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the tapered roller bearing (outer race) and counter driven gear shim from the hybrid vehicle generator assembly.

      SST
      09527-20011
      09527-21011
      09612-65014   ( 09612-01030 )

      Note

      Be careful not to damage the hybrid vehicle generator assembly.

  20. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY TYPE T OIL SEAL (for RH Side)


    1. A01NLOIE01

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

      SST
      09308-36010

  21. REMOVE INPUT SHAFT TYPE T OIL SEAL


    1. A01NIJ2E01
      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
      09502-24010

      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.

  22. REMOVE NO. 2 TRANSMISSION OIL STRAINER


    1. A01NMUE

      Remove the bolt and No. 2 transmission oil strainer from the hybrid vehicle motor assembly.

    2. A01NII8

      Remove the O-ring from the No. 2 transmission oil strainer.

  23. REMOVE PARKING LOCK PAWL


    1. A01NI4F

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

  24. REMOVE PAWL STOPPER PLATE


    1. A01NI9A

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

  25. REMOVE TORSION SPRING


    1. A01NNBM

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

  26. REMOVE PARKING LOCK SLEEVE


    1. A01NKJG

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

  27. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY


    1. A01NJ3Q

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

  28. REMOVE RETAINER SPRING


    1. A01NKSZ

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

  29. REMOVE NO. 1 PARKING LOCK SHAFT


    1. A01NJ11

      Using a hammer and a screwdriver, unstake the spacer.

    2. A01NITH

      Align the cutout of the spacer with the slotted spring pin hole, and then using a 5 mm pin punch and a hammer, drive out the slotted spring pin from the No. 1 parking lock shaft.

    3. A01NKMZ

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

  30. REMOVE PARKING LOCK ROD SUB-ASSEMBLY


    1. A01NNC1E01
      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. A01NIEX

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

  31. REMOVE NO. 1 TRANSMISSION MAGNET


    1. A01NLGV

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

  32. REMOVE INPUT SHAFT ASSEMBLY


    1. A01NLVH

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

  33. REMOVE PLANETARY SUN GEAR


    1. A01NKPXE01
      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.

  34. REMOVE THRUST NEEDLE ROLLER BEARING


    1. A01NNFKE01
      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.

  35. REMOVE DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A01NJCE

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

  36. REMOVE COUNTER DRIVEN GEAR SUB-ASSEMBLY


    1. A01NKMM

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

  37. REMOVE COUNTER DRIVE GEAR SUB-ASSEMBLY


    1. A01NJEG

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

  38. REMOVE NO. 1 REAR PLANETARY GEAR ASSEMBLY


    1. A01NLSY

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

  39. INSPECT NO. 1 REAR PLANETARY GEAR ASSEMBLY


    1. A01NLJB

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

      Standard Clearance
      0.2 to 0.8 mm (0.00787 to 0.0315 in.)

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

  40. REMOVE PLANETARY OIL RECEIVER


    1. A01NJIM

      Remove the planetary oil receiver from the hybrid vehicle motor assembly.

  41. REMOVE TRANSMISSION OIL STRAINER


    1. A01NKC5

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

    2. A01NKJ2

      Remove the O-ring from the transmission oil strainer.

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


    1. A01NJN7E01

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

      SST
      09950-60010   ( 09951-00750 )
      09950-70010   ( 09951-07200 )

  43. REMOVE TAPERED ROLLER BEARING (OUTER RACE) (for LH Side)


    1. A01NKN7E01

      Using SST, remove the tapered roller bearing (outer race) from the hybrid vehicle motor assembly.

      SST
      09308-36010

      Note

      Be careful not to damage the hybrid vehicle motor assembly.

  44. REMOVE TAPERED ROLLER BEARING (OUTER RACE) (for LH Side)


    1. A01NIY0E01

      Using SST, remove the tapered roller bearing (outer race) from the hybrid vehicle motor assembly.

      SST
      09308-36010

      Note

      Be careful not to damage the hybrid vehicle motor assembly.

  45. REMOVE PARKING LOCK SHAFT TYPE T OIL SEAL


    1. A01NL0GE01
      Text in Illustration
      *a Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the parking lock shaft type T oil seal from the hybrid vehicle motor assembly.

      Note

      Be careful not to damage the hybrid vehicle motor assembly.

  46. REMOVE TAPERED ROLLER BEARING (INNER RACE) (for LH Side)


    1. A01NL7KE01
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the tapered roller bearing (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 )

  47. REMOVE TAPERED ROLLER BEARING (INNER RACE) (for RH Side)


    1. A01NK3VE01
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the tapered roller bearing (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 )

  48. REMOVE LOCK NUT


    1. Secure the counter driven gear sub-assembly in a vise using aluminum plates.

      Note

      Be careful not to damage the counter driven gear sub-assembly in the vise.

    2. A01NMPZE01

      Using SST and a hammer, loosen the staked part of the lock nut.

      SST
      09930-00010
    3. A01NJ5D

      Using a 41 mm deep socket wrench, remove the lock nut from the counter driven gear sub-assembly.

  49. REMOVE TAPERED ROLLER BEARING (INNER RACE) (for LH Side)


    1. A01NKQRE01
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the tapered roller bearing (inner race) from the counter driven gear sub-assembly.

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

  50. REMOVE TAPERED ROLLER BEARING (INNER RACE) (for RH Side)


    1. A01NKD5E01
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the tapered roller bearing (inner race) from the counter driven gear sub-assembly.

      SST
      09950-00020
      09950-00030
      09950-40011   ( 09957-04010 )
      09950-60010   ( 09951-00320 )

  51. REMOVE STRAIGHT PIN


    1. A01NM1P

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

      Note

      Be careful not to damage the hybrid vehicle motor assembly.