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Home >> Toyota >> 2019 >> Mirai >> Repair and Diagnosis >> Transmission >> Transmission Control Systems >> Hybrid Transaxle System - Service Information >> Hybrid Vehicle Transaxle >> Removal [11/2018 - ] >> Procedure

Removal [11/2018 - ]: Procedure

  1. CAUTIONS FOR HIGH VOLTAGE SYSTEM COMPONENTS 

    Refer to PROCEDURE - Step 1

  2. CAUTIONS FOR INTAKE SYSTEM COMPONENTS 

    Refer to PROCEDURE - Step 3

  3. REMOVE NO. 1 MOTOR UNDER COVER 

    Refer to PROCEDURE - Step 8

  4. REMOVE NO. 2 MOTOR UNDER COVER 

    Refer to PROCEDURE - Step 9

  5. REMOVE REAR MOTOR UNDER COVER LH 

    Refer to PROCEDURE - Step 10

  6. REMOVE REAR MOTOR UNDER COVER RH 

    Refer to PROCEDURE - Step 11

  7. REMOVE FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 2

  8. REMOVE FRONT FLOOR COVER RH 

    Refer to PROCEDURE - Step 3

  9. DRAIN HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 2

  10. REMOVE INVERTER WITH CONVERTER ASSEMBLY 

    Refer to REMOVAL [11/2018 - ]

  11. SEPARATE HEATER WATER INLET B HOSE 
    1. Disengage the clamp to separate the heater water inlet b hose from the FC radiator inlet pipe.
      GTY542131Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. SEPARATE NO. 2 WATER HOSE SUB-ASSEMBLY 
    1. Disengage the clamp to separate the No. 2 water hose sub-assembly from the No. 1 FC cooling water valve outlet hose.
      GTY564880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. SEPARATE FC RADIATOR INLET PIPE 
    1. Remove the 2 bolts to separate the FC radiator inlet pipe from the center frame crossmember sub-assembly.
      GTY542132Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. SEPARATE FC COOLING WATER VALVE INLET PIPE 
    1. Remove the 2 bolts to separate the FC cooling water valve inlet pipe from the inverter cooling outlet pipe.
      GTY542220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. SEPARATE FC COOLING BY-PASS PIPE 
    1. Remove the 2 nuts to separate the FC cooling by-pass pipe from the electric heater sub-assembly.
      GTY542222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. SEPARATE FC COOLING WATER TEMPERATURE CONTROL VALVE 
    1. Disconnect the electric heater sub-assembly connector.
      GTY542211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and 2 nuts to separate the FC cooling water temperature control valve from the electric heater sub-assembly.
      GTY583973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Move the FC cooling water temperature control valve in the direction indicated by the arrow in the illustration.
      GTY542212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not apply excessive force to any of the hoses.

  17. DISCONNECT NO. 1 INVERTER COOLING OUTLET HOSE 

    Refer to PROCEDURE - Step 7

  18. SEPARATE INVERTER COOLING OUTLET PIPE 
    1. Remove the 2 bolts to separate the inverter cooling outlet pipe from the electric heater sub-assembly.
      GTY542214Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE UPPER NO. 1 RELAY BLOCK COVER 

    Refer to PROCEDURE - Step 4

  20. REMOVE NO. 1 RELAY BLOCK COVER 

    Refer to PROCEDURE - Step 51

  21. DISCONNECT MOTOR WIRE 
    1. Disconnect the 3 connectors.
      GTY542134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts to disconnect the motor wire.
    3. Disengage the 4 clamps to separate the motor wire.
    4. Disconnect the 5 connectors.
      GTY542126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disengage the 5 clamps to separate the motor wire.
  22. REMOVE FCV TRACTION MOTOR BOND CABLE ASSEMBLY 
    1. Remove the 3 bolts and FCV traction motor bond cable assembly from the center frame crossmember sub-assembly, FC air compressor with motor assembly and FCV transaxle with motor assembly.
      GTY542175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. SEPARATE MOTOR CABLE 
    WARNING:

    Wear insulated gloves.

    1. Disengage the clamp to separate the motor cable from the motor cable bracket.
      GTY583975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  25. SECURE STEERING WHEEL 

    Refer to PROCEDURE - Step 2

  26. REMOVE COLUMN HOLE COVER SILENCER SHEET 

    Refer to PROCEDURE - Step 3

  27. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 4

  28. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 26

  29. REMOVE FRONT DRIVE SHAFT ASSEMBLY 

    Refer to REMOVAL [11/2018 - ]

  30. SEPARATE HYDROGEN PUMP CABLE BRACKET 
    1. Remove the bolt to separate the hydrogen pump cable bracket from the rear motor mounting insulator.
      GTY542128Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. SEPARATE FC STACK COOLING WATER OUTLET BRACKET 
    1. Remove the bolt to separate the FC stack cooling water outlet bracket from the rear motor mounting insulator.
      GTY542129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. DISCONNECT NO. 3 MOTOR COOLING HOSE 
    1. Slide the hose clip and disconnect the No. 3 motor cooling hose from the oil cooler union sub-assembly.
      GTY541921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. DISCONNECT NO. 1 MOTOR COOLING HOSE 
    1. Slide the hose clip and disconnect the No. 1 motor cooling hose from the oil cooler inlet tube sub-assembly.
      GTY541924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 20

  35. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH 

    Refer to PROCEDURE - Step 21

  36. SUPPORT FCV TRANSAXLE WITH MOTOR ASSEMBLY 
    1. Using a transmission jack, support the FCV transaxle with motor assembly.
      GTY569608Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Lashing Belt
      NOTE:
      • Adjust the attachment of the transmission jack to securely fix the FCV transaxle with motor assembly to the transmission jack.
      • Using a lashing belt or a rope, fix the FCV transaxle with motor assembly to the transmission jack.
  37. REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 23

  38. REMOVE FRONT SUSPENSION MEMBER REAR BRACE LH 

    Refer to PROCEDURE - Step 24

  39. REMOVE FRONT SUSPENSION MEMBER REAR BRACE RH 

    HINT: 

    Perform the same procedure as for the LH side.

  40. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 26

  41. SEPARATE FC COOLING WATER PUMP ASSEMBLY 
    1. Remove the bolt and 2 nuts from the FC cooling water pump assembly.
      GTY542216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an E8 "TORX" socket wrench, remove the 2 stud bolts to separate the FC cooling water pump assembly from the FC air compressor with motor assembly.
      GTY542209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Suspend the FC cooling water pump assembly with a piece of rope so as not to apply excessive force to the wire harness and hoses.

  42. SUPPORT FC AIR COMPRESSOR WITH MOTOR ASSEMBLY 
    1. Using a height adjustment attachment and a plate lift attachment, support the FC air compressor with motor assembly with a engine lifter or a transmission jack.
      GTY563036Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Attachment Placement Position
  43. REMOVE MOTOR MOUNTING INSULATOR LH 
    1. Remove the nut to separate the motor mounting insulator LH from the motor mounting bracket LH.
      GTY542124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts and motor mounting insulator LH from the center frame crossmember sub-assembly.
      GTY598318Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE FCV TRANSAXLE WITH MOTOR ASSEMBLY 
    1. Operate the transmission jack to slightly tilt the FCV transaxle with motor assembly downward.
      NOTE:

      Be careful not to apply excessive force to the wire harnesses and hoses, etc.

    2. Remove the bolt to separate the FC air compressor cable bracket from the FCV transaxle with motor assembly.
      GTY598317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 7 bolts.
      GTY589511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Knock Pin
      NOTE:

      Make sure that the FCV transaxle with motor assembly is clear of all wire harnesses and hoses.

    4. Disengage the 2 knock pins and separate the FCV transaxle with motor assembly from the FC air compressor with motor assembly.
    5. Because the motor portion of the FC air compressor with motor assembly is inside the housing of the FCV transaxle with motor assembly, use the following procedure to remove the FCV transaxle with motor assembly without allowing the housing to contact the motor.
      GTY541468Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Be careful to avoid contact with this area.
      1. Slightly move the FCV transaxle with motor assembly, together with the transmission jack, towards the outer side of the vehicle. (Step 1)
        NOTE:

        Do not allow the FCV transaxle with motor assembly to contact the front side member.

      2. Operate the transmission jack and slightly tilt the FCV transaxle with motor assembly. (Step 2)
        NOTE:

        Do not tilt the FCV transaxle with motor assembly any more than necessary.

      3. Operate the transmission jack and slightly lower the FCV transaxle with motor assembly. (Step 3)
        NOTE:

        Do not allow the FCV transaxle with motor assembly to contact the FC air compressor with motor assembly.

      4. Repeat Step 1 through Step 3 several times to remove the FCV transaxle with motor assembly.
  45. REMOVE MOTOR WIRE 
    1. Disconnect the 3 connectors.
      GTY542160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 7 clamps to remove the motor wire from the FCV transaxle with motor assembly.
  46. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. Remove the 2 bolts and 2 wire harness clamp brackets from the FCV transaxle with motor assembly.
      GTY542161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE FRONT MOTOR MOUNTING INSULATOR 
    1. Remove the nut and front motor mounting insulator from the front motor mounting bracket.
      GTY598305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE FRONT MOTOR MOUNTING BRACKET 
    1. Remove the 4 bolts and front motor mounting bracket from the FCV transaxle with motor assembly.
      GTY542162Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE REAR MOTOR MOUNTING INSULATOR 
    1. Remove the bolt and rear motor mounting insulator from the rear motor mounting bracket.
      GTY598304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE REAR MOTOR MOUNTING BRACKET 
    1. Remove the 3 bolts and rear motor mounting bracket from the FCV transaxle with motor assembly.
      GTY542158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE MOTOR MOUNTING BRACKET LH 
    1. Remove the 4 bolts and motor mounting bracket LH from the FCV transaxle with motor assembly.
      GTY542157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. SEPARATE MOTOR CABLE 
    WARNING:

    Wear insulated gloves.

    1. Disengage the clamp to separate the motor cable from the motor cable bracket.
      GTY598302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE AUTOMATIC TRANSMISSION CASE COVER 
    1. Disengage the 2 grommets to remove the automatic transmission case cover from the No. 2 automatic transmission case cover.
      GTY561184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  54. REMOVE FCV TRANSAXLE MASS DAMPER 
    1. Remove the bolt and FCV transaxle mass damper from the FCV transaxle with motor assembly.
      GTY542151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. REMOVE NO. 2 AUTOMATIC TRANSMISSION CASE COVER 
    1. Remove the clip.
      GTY542152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and No. 2 automatic transmission case cover from the FCV transaxle with motor assembly.
  56. REMOVE MOTOR CABLE BRACKET 
    1. Remove the bolt and motor cable bracket from the FCV transaxle with motor assembly.
      GTY542178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. REMOVE STRAIGHT SCREW PLUG 
    1. Using a 10 mm hexagon socket wrench, remove the straight screw plug and gasket from the FCV transaxle with motor assembly.
      GTY597924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Gasket
  58. REMOVE OIL COOLER UNION SUB-ASSEMBLY 
    1. Loosen the union bolt.
      GTY597348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Gasket
    2. Remove the bolt and No. 2 oil cooler tube clamp from the No. 1 oil cooler tube clamp.
    3. Remove the union bolt, oil cooler union sub-assembly and gasket from the FCV transaxle with motor assembly.
  59. REMOVE OIL COOLER INLET TUBE SUB-ASSEMBLY 
    1. Using a 17 mm union nut wrench, loosen the flare nut.
      GTY542180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      While holding the transaxle housing union in place, loosen the flare nut.

    2. Remove the bolt and No. 2 oil cooler tube clamp from the No. 1 oil cooler tube clamp.
    3. Separate the flare nut to remove the oil cooler inlet tube sub-assembly from the FCV transaxle with motor assembly.
  60. REMOVE TRANSAXLE HOUSING UNION 
    1. Remove the transaxle housing union from the FCV transaxle with motor assembly.
      GTY546344Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 O-ring
    2. Remove the O-ring from the transaxle housing union.
  61. REMOVE TRANSAXLE BREATHER PLUG 
    1. Using a 14 mm deep socket wrench, remove the transaxle breather plug from the FCV transaxle with motor assembly.
      GTY542174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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