HYBRID TRANSAXLE OIL SEAL REPLACEMENT

DRAIN HYBRID TRANSAXLE FLUID

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

   

   Text in Illustration

   *1	Filler Plug
   *2	Drain Plug

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

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

   Torque:

   39 N*m  { 400 kgf*cm, 29 ft.*lbf }

REMOVE FRONT AXLE SHAFT NUT

1. 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.

SEPARATE FRONT STABILIZER LINK ASSEMBLY

1. Remove the nut and separate the front stabilizer link assembly from the front shock absorber assembly.

   

   If the ball joint turns together with the nut, use a wrench to hold the stud bolt.

SEPARATE FRONT SPEED SENSOR

1. Remove the bolt and clamp, and separate the front speed sensor and front flexible hose from the front shock absorber assembly.

   

   Note

   Be sure to separate the front speed sensor from the front shock absorber assembly completely.

SEPARATE TIE ROD ASSEMBLY

1. Remove the cotter pin and nut.

   

2. Install SST to the tie rod assembly LH.

   

   SST

   09960-20010   ( 09961-02060 )

   Note

   Make sure that the lower ends of the tie rod assembly LH 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 assembly LH from the steering knuckle.

   

   Text in Illustration

   *1	Center Nut	-	-
   *a	String	*b	Grease Application Area
   	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.

SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY

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

   

SEPARATE FRONT DRIVE SHAFT ASSEMBLY

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

   

   Text in Illustration

   *a

   Matchmark

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.

REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

1. Using SST, remove the front drive shaft assembly LH.

   

   SST

   09520-00031

   09520-01010

   Note

   • Do not damage the hybrid vehicle transaxle assembly type T oil seal.

   • Do not damage the front axle inboard joint boot.

   • Do not drop the front drive shaft assembly LH.

REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

1. Separate the bearing bracket hole snap ring from the drive shaft bearing bracket.

   

2. Remove the bolt and front drive shaft assembly RH from the drive shaft bearing bracket.

   Note

   • Do not damage the hybrid vehicle transaxle assembly type T oil seal.

   • Do not damage the front axle inboard joint boot.

   • Do not drop the front drive shaft assembly RH.

3. Remove the bearing bracket hole snap ring from the front drive shaft assembly RH.

REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH

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

   

REMOVE DRIVE SHAFT BEARING BRACKET

1. Remove the 3 bolts and drive shaft bearing bracket.

   

INSTALL DRIVE SHAFT BEARING BRACKET

1. Install the drive shaft bearing bracket with the 3 bolts.

   Torque:

   64 N*m  { 653 kgf*cm, 47 ft.*lbf }

INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH

1. Install a new front drive shaft hole snap ring LH.

   Note

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

INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

1. Coat the spline of the front drive inboard joint assembly with ATF.

2. Coat the lip of the hybrid vehicle transaxle assembly type T oil seal with MP grease.

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

   

   Note

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

   • Do not damage the hybrid vehicle transaxle assembly type T oil seal.

   • Do not damage the front axle inboard joint boot.

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

   Tech Tips

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

4. Apply mineral oil base grease to the areas indicated by the arrows in the illustration on the front drive shaft assembly LH contact surface of the front axle hub bearing.

   

   Text in Illustration

   Mineral Oil Base Grease

   Tech Tips

   Apply 0.1 to 0.3 g (0.00353 to 0.0106 oz.) of mineral oil base grease to each area.

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

   

   Text in Illustration

   *a

   Matchmark

   Note

   Be careful not to damage the front axle outboard joint boot or speed sensor rotor.

INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

1. Coat the spline of the front drive inboard joint assembly with ATF.

2. Coat the lip of the hybrid vehicle transaxle assembly type T oil seal with MP grease.

3. Install a new bearing bracket hole snap ring to the front drive shaft assembly RH.

4. Install the front drive shaft assembly RH.

   Note

   • Do not damage the hybrid vehicle transaxle assembly type T oil seal.

   • Do not damage the front axle inboard joint boot.

   • When inserting the front drive shaft assembly RH, keep it level.

5. Install the bearing bracket hole snap ring and a new bolt.

   

   Torque:

   32 N*m  { 330 kgf*cm, 24 ft.*lbf }

6. Apply mineral oil base grease to the areas indicated by the arrows in the illustration on the front drive shaft assembly RH contact surface of the front axle hub bearing.

   

   Text in Illustration

   Mineral Oil Base Grease

   Tech Tips

   Apply 0.1 to 0.3 g (0.00353 to 0.0106 oz.) of mineral oil base grease to each area.

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

   

   Text in Illustration

   *a

   Matchmark

   Note

   Be careful not to damage the front axle outboard joint boot or speed sensor rotor.

CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY

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

   Torque:

   75 N*m  { 765 kgf*cm, 55 ft.*lbf }

CONNECT TIE ROD ASSEMBLY

1. Connect the tie rod assembly LH to the steering knuckle with the nut.

   Torque:

   49 N*m  { 500 kgf*cm, 36 ft.*lbf }

2. Install a new cotter pin.

   Note

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

INSTALL FRONT SPEED SENSOR

1. Install the front speed sensor and front flexible hose to the front shock absorber assembly 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 speed sensor harness bracket first and then the front flexible hose.

INSTALL FRONT STABILIZER LINK ASSEMBLY

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

   Torque:

   125 N*m  { 1275 kgf*cm, 92 ft.*lbf }

   If the ball joint turns together with the nut, use a wrench to hold the stud bolt.

INSTALL FRONT AXLE SHAFT NUT

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

   Note

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

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

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

   

   Torque:

   294 N*m  { 2998 kgf*cm, 217 ft.*lbf }

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

ADD HYBRID TRANSAXLE FLUID

1. Add transaxle fluid until the fluid level is between 0 to 5 mm (0 to 0.197 in.) from the bottom lip of the filler plug opening.

   

   Text in Illustration

   *1	Filler Nozzle
   *2	Filler Plug

   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
   3.7 liters (3.9 US qts, 3.2 Imp. 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 5 mm (0 to 0.197 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.

INSPECT HYBRID TRANSAXLE FLUID

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

   

   Text in Illustration

   *1	Filler Plug

2. Check that the fluid level is between 0 to 5 mm (0 to 0.197 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:

   39 N*m  { 400 kgf*cm, 29 ft.*lbf }

INSTALL FRONT WHEELS

Torque:

103 N*m  { 1049 kgf*cm, 76 ft.*lbf }