Toyota Prius 2002-06

Transaxle Removal & Installation

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Fig. Transaxle unit, engine unit and related components-2002-03 models

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable. Wait at least 90 seconds after disconnecting the negative battery cable to prevent possible airbag and seat belt pretensioner activation.
  4.  
  5. Drain the transaxle fluid.
  6.  
  7. Remove the engine and transaxle as an assembly.
  8.  
  9. Remove the 2 bolts and dust cover.
  10.  
  11. Remove the 6 bolts and separate the transaxle from the engine.
  12.  
  13. Using SST 09213-58012 and 09330-00021, hold the crankshaft pulley, remove the 6 bolts and damper disc and spring.
  14.  
  15. Using SST 09213-58012 and 09330-00021, hold the crankshaft pulley, remove the 6 bolts and flywheel.
  16.  

To install:

  1. Apply adhesive to 2 or 3 threads of the bolt end.
  2.  
  3. Install and uniformly tighten the new 6 bolts in several passes, in a star sequence to 62 ft. lbs. (84 Nm).
  4.  
  5. Retighten the flywheel bolts by 90 degrees in the same star sequence.

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    Fig. Flywheel bolt tightening sequence-2002-03 models



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    Fig. Damper disc and spring bolt tightening sequence-2002-03 models

  6.  
  7. Insert SST 09301-001 10 in the damper disc, then insert them in the flywheel. Take care not to insert damper disc in the wrong direction.
  8.  
  9. Set the damper spring on the damper disc.
  10.  
  11. Install and tighten the 6 bolts in a star sequence, starting the bolt locating near the knock pin on the top. Tighten the bolts to 12 ft. lbs. (16 Nm).
  12.  
  13. Following the star sequence, tighten the bolts at a time evenly. Move SST up and down, right and left lightly, after checking that the disc in the center, tighten the bolts.
  14.  
  15. Attach the transaxle to the engine, and install the 6 bolts. Torque the bolts to 24 ft. lbs. (33 Nm).
  16.  
  17. Install the dust cover.
  18.  
  19. Install the left engine mounting bracket. Torque the bolts to 38 ft. lbs. (52 Nm).
  20.  
  21. Fill the transaxle with the correct amount and type of fluid.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Perform the test drive of the vehicle and check the function of the engine and transaxle.
  26.  



Click image to see an enlarged view

Fig. Transaxle unit and related components-2004-06 Prius models

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable. Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
  4.  
  5. While wearing insulating gloves, slide up the lever of the service plug grip and remove while turning the lever to the left. Be sure to insulate the service plug with insulating tape.
    CAUTION
    Do not touch the high voltage connectors and terminals for 5 minutes after removing the service plug grip.

  6.  
  7. Drain engine coolant and transaxle fluid.
  8.  
  9. Remove or disconnect the following:

    Front wheels
     
    Engine under covers
     
    Hood
     
    Left and right front wiper arms
     
    Cowl top front panel
     

  10.  
  11. While wearing insulating gloves, remove the inverter with converter assembly as follows:


    1. Remove the left and right engine under covers.
    2.  
    3. Drain the HV coolant.
    4.  
    5. Remove the radiator support opening cover.
    6.  
    7. Remove the inverter cover.
    8.  
    9. Verify that there is 0V at the inverter with converter, using a voltmeter utilizing a measuring range of DC 400V or more.

      Click image to see an enlarged view

      Fig. Verifying that there is 0V at the inverter with converter-Prius

    10.  
    11. Again, verify that there is 0V by measuring the voltage between the terminals of the three phase connector (U-V, V-W, U-W), using a voltmeter utilizing a measuring range of DC 400V or more.

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      Fig. Measuring voltage between the terminals of the three phase connector-Prius

    12.  
    13. Disconnect the No. 1, No. 2 and No. 6 inverter cooling hoses.
    14.  
    15. Disconnect the No. 1 circuit breaker sensor by first moving the outer section away toward the wire side.
    16.  
    17. Disconnect the 2 frame wire connectors from the inverter with converter assembly and protect the electrode and connector parts with insulating tape.
    18.  
    19. Use a small screwdriver to lift up the green lock pin, then disconnect the connector for the air conditioning inverter.
    20.  
    21. Disconnect any remaining wiring connectors including the engine main wiring harness.
    22.  
    23. Remove the mounting bolts and disconnect the MG1 and MG2 power cables. Protect the connector parts with insulating tape.
    24.  
    25. Remove the 3 mounting bolts and the inverter with converter assembly.
    26.  

  12.  
  13. Remove or disconnect the following:

    Air cleaner assembly
     
    Associated wiring harnesses and clamps
     
    3 bolts and transmission case cover from the transaxle
     
    bolt and ground wire
     
    4 clamps and 3 cooling hoses from inverter
     
    Front exhaust pipe
     
    Left and right front axle hub nuts
     
    Left front stabilizer link
     
    Left and right tie rod ends
     
    Left and right front lower control arms
     
    Left and right front axle hub/bearing assemblies
     
    Left and right drive shafts
     
    Engine torque rod
     
    Front suspension crossmember
     
    2 PCV hoses
     

  14.  
  15. Install the No. 1 (12281-22021) and No. 2 (12281-15040) engine hangers in the correct direction. Torque the hanger bolt (91512-B1016) to 28 ft. lbs. (38 Nm).
  16.  
  17. Attach an engine chain hoist to the engine hangers to keep the engine suspended.
    WARNING
    Do not attempt to hang the engine by hooking the chain to any other parts.

  18.  
  19. Using a transmission jack, support the hybrid vehicle transaxle.
  20.  
  21. Remove the nut and disconnect the No. 3 engine mounting bracket from the engine mounting insulator.
  22.  
  23. Remove the 2 bolts, starter cover and housing side cover.
  24.  
  25. Remove the 6 bolts and transaxle unit.
    NOTE
    To avoid damage to the knock pin, do not pry the connecting portion of the HV transaxle and the engine.

  26.  
  27. Remove the No. 6 clamp and inverter cooling hose.
  28.  
  29. Remove the 3 bolts and No. 3 engine mounting bracket.
  30.  
  31. Remove the 6 bolts and clamp.
  32.  

To install:

  1. Install the clamp in position with the 6 bolts and tighten to 80 inch lbs. (9 Nm).
  2.  
  3. Install the No. 3 engine mounting bracket with the 3 bolts and tighten to 38 ft. lbs. (52 Nm).
  4.  
  5. Connect the No. 6 inverter cooling hose and install the clamp.
  6.  
  7. Install the transaxle to the engine in the vehicle. Tighten the 6 bolts to 24 ft. lbs. (33 Nm).
    NOTE
    Ensure that the knock pin is installed on the engine side. Place the transaxle in a horizontal position and align the knock pin to its hole. Then tighten the 6 bolts in the correct positions.



    Click image to see an enlarged view

    Fig. Correct positions of the transaxle mounting bolts-2004-06 Prius

  8.  
  9. Install the housing side cover and starter cover and tighten the 2 bolts to 23 ft. lbs. (32 Nm).
  10.  
  11. Install the No. 3 engine mounting bracket to the engine mounting insulator with the nut. Torque the nut to 59 ft. lbs. (80 Nm).
  12.  
  13. Remove the engine hangers.
  14.  
  15. Install or connect the following:

    2 PCV hoses
     
    Front suspension crossmember. Torque the left and right front corner bolts to 83 ft. lbs. (113 Nm). Torque the left and right rear corner bolts to 116 ft. lbs. (157 Nm).
     
    Engine torque rod. Torque the 2 nuts and 2 bolts, at the engine, to 74 ft. lbs. (100 Nm). Torque the 2 nuts and 2 bolts, at the body side, to 41 ft. lbs. (56 Nm).
     
    Left and right drive shafts
     
    Left and right front axle hub/bearing assemblies
     
    Left and right front lower control arms
     
    Left and right tie rod ends
     
    Left front stabilizer link
     
    Left and right front axle hub nuts
     
    Front exhaust pipe
     
    3 cooling hoses to the inverter with the 4 clamps
     
    Ground wire and bolt tightened to 80 inch lbs. (9 Nm)
     
    Transmission case cover to the transaxle with 3 bolts tightened to 62 inch lbs. (7 Nm)
     
    Associated wiring harnesses and clamps
     
    Air cleaner assembly
     

  16.  
  17. While wearing insulating gloves, install the inverter with converter assembly as follows:


    1. Install the inverter with converter assembly and tighten the three mounting bolts to 16 ft. lbs. (21 Nm).
    2.  
    3. Connect the MG1 and MG2 power cables and tighten the mounting bolts to 71 inch lbs. (8 Nm).
    4.  
    5. Connect any remaining wiring connectors including the engine main wiring harness. Be sure to insert the grommet of the engine main wiring harness into the U-shaped groove of the inverter case.
    6.  
    7. Engage the connector for the air conditioning inverter and secure by pushing in the lock pin..
    8.  
    9. Connect the 2 frame wire connectors to the inverter with converter assembly.
    10.  
    11. Connect the No. 1 circuit breaker sensor.
    12.  
    13. Connect the No. 6, No. 2 and No. 1 inverter cooling hoses.
    14.  
    15. Install the inverter cover and tighten the mounting fasteners to 8 ft. lbs. (11 Nm).
    16.  
    17. Install the radiator support opening cover.
    18.  
    19. Install the left and right engine under covers.
    20.  

  18.  
  19. Install or connect the following:

    Cowl top front panel
     
    Left and right front wiper arms
     
    Hood
     
    Engine under covers
     
    Front wheels
     

  20.  
  21. While wearing insulating gloves, joint the service plug grip with the HV battery. While pushing the service plug grip to the right, rotate the lever to the right. Slide the lever down to lock the service plug grip in place.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Add transaxle fluid and engine coolant. Check systems for leaks.
  26.  
  27. Inspect and adjust the front wheel alignment.
  28.  
  29. Perform calibration.
  30.  
  31. Perform initialization.
  32.  

 
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