HYBRID VEHICLE TRANSAXLE UNIT DISASSEMBLY

CAUTION / NOTICE / HINT

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.

    A005DABE03
    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 - -

PROCEDURE


  1. INSPECT INPUT SHAFT END PLAY

    Click here

  2. REMOVE GENERATOR CABLE


    1. A005AO5

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

    2. A0059TH

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

    3. A005F2D

      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. A0059W8

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

    2. A005CM5

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

    3. A005COK

      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. A005BYG

      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. A005DL9

      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. A005E7X

      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. A005E3J

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

    2. A005DYQ

      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. A005AL2E04
      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. A005C53

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

  8. REMOVE OIL PUMP DRIVE SHAFT


    1. A005C4V

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

  9. SECURE HYBRID VEHICLE TRANSAXLE ASSEMBLY


    1. A005DBME04
      Text in Illustration
      *1 Wooden Block
      *2 Resolver Sensor Connector
      *a Installation area of the Transmission Oil Pump Cover Sub-assembly
      A005CWR 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. A0059ZF

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

  11. REMOVE DRAIN PLUG


    1. A005CTG

      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. A005CHT

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

    2. A0059N2

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

    3. A005B6IE05
      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. A005E5Y

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

    2. A005E40E06
      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 MOTOR WATER JACKET COVER ASSEMBLY


    1. A005DOW

      Remove the 10 bolts from the motor water jacket cover assembly.

    2. A005BYTE01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, remove the 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.

  15. 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.

      A005A5WE05
      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. A005ER7

      Remove the 8 bolts from the hybrid vehicle generator assembly.

    3. A005DZB

      Remove the 8 bolts from the hybrid vehicle generator assembly.

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

    5. A005F3X

      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.

  16. REMOVE TRANSAXLE HOUSING OIL SEPARATOR


    1. A005B96

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

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


    1. A005CUXE05

      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 )

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


    1. A005CVQ

      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.

  19. REMOVE INPUT SHAFT TYPE T OIL SEAL


    1. A005DKCE05
      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.

  20. REMOVE COUNTER DRIVEN GEAR SHIM


    1. A005CEJ

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

  21. REMOVE PARKING LOCK PAWL


    1. A005ESO

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

  22. REMOVE PAWL STOPPER PLATE


    1. A005ACK

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

  23. REMOVE TORSION SPRING


    1. A005CRS

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

  24. REMOVE PARKING LOCK SLEEVE


    1. A005EWO

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

  25. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY


    1. A005DMT

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

  26. REMOVE RETAINER SPRING


    1. A005E2A

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

  27. REMOVE NO. 1 PARKING LOCK SHAFT


    1. A005AIF

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

    2. A005EK1

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

    3. A005BUP

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

  28. REMOVE PARKING LOCK ROD SUB-ASSEMBLY


    1. A005AVME01
      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. A005BKL

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

  29. REMOVE NO. 1 TRANSMISSION MAGNET


    1. A005BJR

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

  30. REMOVE INPUT SHAFT ASSEMBLY


    1. A005B78

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

  31. REMOVE PLANETARY SUN GEAR


    1. A005A16E01
      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.

  32. REMOVE THRUST NEEDLE ROLLER BEARING


    1. A005DYUE01
      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.

  33. REMOVE DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A005DN5

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

  34. REMOVE COUNTER DRIVEN GEAR SUB-ASSEMBLY


    1. A005E86

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

  35. REMOVE COUNTER DRIVE GEAR SUB-ASSEMBLY


    1. A005B2R

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

  36. REMOVE NO. 1 REAR PLANETARY GEAR ASSEMBLY


    1. A005BS6

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

  37. INSPECT NO. 1 REAR PLANETARY GEAR ASSEMBLY

    Click here

  38. REMOVE REAR PLANETARY SUN GEAR


    1. A005CJJ

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

    2. A005AS7

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

  39. REMOVE TRANSMISSION OIL STRAINER


    1. A005B1G

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

    2. A005EJ2

      Remove the O-ring from the transmission oil strainer

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


    1. A005EN2E01

      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 )

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


    1. A005DMP

      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.

  42. REMOVE SHIFT CONTROL ACTUATOR SEAL


    1. A005DHME06
      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.

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


    1. A005AUJE04
      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 )

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


    1. A005DQME04
      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 )

  45. REMOVE RADIAL BALL BEARING (LH SIDE)


    1. A005EPYE03
      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 )

  46. REMOVE RADIAL BALL BEARING (RH SIDE)


    1. A005D07E05
      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 )

  47. REMOVE STRAIGHT PIN


    1. A005EOR

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