TOYOTA PRIUS 2001 Service Repair Manual

D09920Drain Plug
D09925
Oil Level
0 ± 5 mm
HT005±01
D09921Drain Plug
D09778
Shop Rag
D09899
HT±6
± HYBRID TRANSAXLEHYBRID TRANSAXLE UNIT
1379 Author: Date:
2001 PRIUS (RM778U)
HYBRID TRANSAXLE UNIT
ON±VEHICLE REPAIR
1. REPLACE TRANSAXLE OIL
Fluid type: ATF Type T±IV
Capacity: 4.6 liters (4.9 US qts, 4.0 Imp. qts)
Torque: 49 N´m (498 kgf´cm, 36 ft´lbf)
2. REPLACE COOLANT
(a) Remove the reservoir tank cap of the inverter.
(b) Remove the drain plug and drain the coolant.
(c) Install the drain plug with a new gasket.
(d) Loosen the 2 bleeder plugs and connect the hoses.
HINT:
To prevent coolant from splashing, place a shop rag on the
overflow pipe as shown in the illustration.
(e) Supply coolant from the reservoir tank.
(f) Supply coolant until coolant level in the hose connected
to the bleeder plugs reaches the same level with FULL of
the reservoir tank as shown in the illustration.
(g) Tighten the 2 bleeder plugs.
(h) Turn the ignition switch ON and active the water pump.
(i) Leave it as it is for approx. 20 seconds.
(j) Turn the ignition switch OFF.
(k) Loosen the 2 bleeder plugs to bleed air.
(l) Close the 2 bleeder plugs again.

D09898
Coolant Level
± HYBRID TRANSAXLEHYBRID TRANSAXLE UNIT
HT±7
1380 Author: Date:
2001 PRIUS (RM778U)
(m) Report the step (h) to (l) until the operation sound of the
pump becomes lower and Coolant in the reservoir tank
moves faster.
(n) With the ignition switch ON, wait for applox. 5 minutes.
(o) Adjust the coolant level inside the reservoir tank as shown
in the illustration.

HT00A±01
D09787
Non±reusable part
N´m (kgf´cm, in.´lbf): Specified torque Power Cable Cover
High±Voltage Cable Housing Tube


Oil Seal
Motor Generator
No. 1 Assembly
Water Jacket Union
Wiring Harness Connector

Gasket
Drain PlugLock Sleeve
Cam Guide Sleeve
Sleeve Bracket
Torsion Spring
Parking Lock Pawl Shaft Lock Clamp
5.4 (55, 48 in.´lbf)
Parking Lock Pawl
Counter Driven Gear Assembly
Outer Race
50 (510, 37)
15 (152, 11)
13 (130, 9)
39 (400, 29)
5.5 (56, 49 in.´lbf)
Outer RaceOuter Race
Shim
Shim
Outer Race
Differential Case Assembly
Shim
Chain
Counter Drive Gear Assembly
Input Shaft AssemblyNeedle Roller Bearing
Bearing RaceDrive SprocketPlanetary Ring Gear
Bearing Race
Ring Gear FlangeShim
18 (183, 13)
4.8 (48, 42 in.´lbf)5.5 (56, 49 in.´lbf)
12.7 (130, 9)
Screw Plug25 (250, 18)
x 13
5.5 (56, 49 in.´lbf)
Needle Roller Bearing
HT±12
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
1385 Author: Date:
2001 PRIUS (RM778U)
HYBRID TRANSAXLE ASSEMBLY
COMPONENTS

D09916
13 (130, 10)
x 5
Oil Seal

Parking Shaft Cover
Washer
Parking Lock Shaft
PinSpacer


Parking Lock Lever No. 3
Mounting Bracket
Motor Water Jacket Cover
5.5 (56, 49 in.´lbf)x 6
Parking Cover
5.5 (56, 49 in.´lbf)
x 6 Detent Spring
Detent Spring Cover
10 (100, 7)
Oil Seal
Screw Plug
24.5 (250, 18)
Filler Plug
39 (400, 29)
Gasket

Screw Plug
24.5 (250, 18)
25 (250, 18)x 8
50 (510, 37)
Filler Plug
39 (400, 29)
Gasket

Wiring Harness Connector
5.5 (56, 49 in.´lbf)
5.5 (56, 49 in.´lbf)
Oil Pump Drive Shaft
Driven Rotor
Drive Rotor
O±Ring
O±Ring

Magnet
Oil Strainer
Gasket

5.5 (56, 49 in.´lbf)
Oil Pan
7.6 (77, 67 in.´lbf)x 12
Gasket

Drain Plug

Non±reusable part
N´m (kgf´cm, in.´lbf): Specified torqueOil Pump Cover
x 5
5.5 (56, 49 in.´lbf)
7.35 (75, 65 in.´lbf)
Plug O±Ring

Motor Generator No. 2
Assembly
Water Jacket Union
Wiring Harness Connector
Breather Plug
11.3 (111, 8)
52 (530, 38)
49 (498, 36)
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
HT±13
1386 Author: Date:
2001 PRIUS (RM778U)

HT00B±01
D09694
D09695
D09696
HT±14
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
2001 PRIUS (RM778U)
DISASSEMBLY
1. INSTALL ENGINE HUNGER
Install the engine hanger onto the MG1 side as shown in the il-
lustration, and lift it up by a chain device.
Engine hanger part No.:
12281±67070, S1228±11781
Bolt part No.:
91642±81045
91642±81265 2 pieces
Nut part No.:
90178±10001
90179±12147 2 pieces
NOTICE:

As the transaxle itself is heavy, place a wood block
underneath to stabilize it and carry out the operation
carefully.

Do not pull or bend the high±voltage cable of the MG1
assembly.

Drain the fluid before disassembly.
2. REMOVE MG1 ASSEMBLY
(a) Remove the 21 bolts.
(b) Using a screwdriver and a hammer, disconnect the MG1
assembly from the MG2 assembly.

D09697
D09698
D09699
D09926
D09700
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
HT±15
2001 PRIUS (RM778U)
HINT:
When separating the MG1 assembly from the MG2 assembly,
to prevent the drive sprocket from being removed with the MG1
assembly, push down the chain part with a taped screwdriver
tip.
3. REMOVE COUNTER DRIVEN GEAR ASSEMBLY
Remove the counter driven gear assembly from the MG2 as-
sembly.
4. REMOVE DIFFERENTIAL CASE ASSEMBLY
Remove the differential case assembly from the MG2 assem-
bly.
5. REMOVE 2 RACE AND NEEDLE ROLLER BEARING
6. REMOVE DRIVE SPROCKET SUB±ASSEMBLY AND
CHAIN

D09701
D09702
D09703
D09704
D09705
HT±16
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
2001 PRIUS (RM778U)
7. REMOVE INPUT SHAFT ASSEMBLY
(a) Remove the input shaft assembly.
(b) Remove the needle roller bearing and 2 bearing races.
8. REMOVE PLANETARY RING GEAR
9. REMOVE RING GEAR FLANGE AND SHIM
10. REMOVE COUNTER DRIVE GEAR AND SHIM
HINT:
Remove the counter drive gear by tapping the case with a plas-
tic hammer.

D09706
D09884
AT0103
D09707
D09883
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
HT±17
2001 PRIUS (RM778U)
11. REMOVE OIL PAN AND GASKET
(a) Remove the drain plug and its gasket.
(b) Remove the 12 bolts.
(c) Remove the oil pan and its gasket.
12. REMOVE MAGNET FROM OIL PAN
13. EXHAUST PARTICLES IN PAN
Remove the magnet and use it to collect any steel chips.
Carefully examine the chips and particles in the oil pan and on
the magnet to indentify what type of wear has occurred in the
transaxle.

Steel (magnetic): bearing, gear and plate wear

Brass (non±magnetic): bushing wear
14. REMOVE OIL STRAINER
(a) Remove the bolt and oil strainer.
(b) Remove the O±ring from the oil strainer.

D09708
D09709
D09710
D09711
D09712
HT±18
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
2001 PRIUS (RM778U)
15. SET MG2 ASSEMBLY
As illustrated, set the MG2 assembly and wood blocks.
16. REMOVE MOUNTING BRACKET
Remove the 3 bolts and mounting bracket.
17. REMOVE WIRING HARNESS CONNECTOR (MG2
side)
Remove the 2 bolts and the 2 wiring harness connectors.
18. REMOVE 2 WATER JACKET UNIONS (MG2 side)
19. REMOVE PARKING COVER
Remove the 6 bolts and parking cover.

D09713
D09714
D09715
D09716
D09717
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
HT±19
2001 PRIUS (RM778U)
20. REMOVE DETENT SPRING COVER AND DETENT
SPRING
Remove the bolt, detent spring cover and detent spring.
21. REMOVE MOTOR WATER JACKET COVER
Remove the 6 bolts and motor water jacket cover.
22. REMOVE PARKING SHAFT COVER
(a) Remove the 5 bolts and parking shaft cover.
(b) Using a screwdriver, remove the oil seal from the cover.
23. REMOVE PARKING LOCK SHAFT ASSEMBLY