2001 TOYOTA PRIUS Service Repair Manual

D09859
SST
D09861
HT±32
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
2001 PRIUS (RM778U)
(f) Using SST and a small torque wrench, measure the
counter driven gear preload.
SST 09564±32011
Preload (Starting torque):
New bearing
3.81 ± 6.10 N´m
(38.85 ± 62.20 kgf´cm, 33.72 ± 53.99 in.´lbf)
Reused bearing
1.91 ± 3.03 N´m
(19.48 ± 30.90 kgf´cm, 16.91 ± 26.82 in.´lbf)
Preload (Turning torque):
3.29 ± 6.66 N´m (60 rpm)
(33.55 ± 67.91 kgf´cm, 29.12 ± 58.95 in.´lbf)
If the preload is not within the specified range, replace the shim
of the counter driven gear LH.
Shim thickness:
MarkThickness mm (in.)MarkThickness mm (in.)
11.25 (0.0492)621.58 (0.0622)
21.28 (0.0504)631.60 (0.0630)
31.31 (0.0516)641.62 (0.0638)
501.34 (0.0528)651.64 (0.0646)
511.36 (0.0535)661.66 (0.0654)
521.38 (0.0543)671.68 (0.0661)
531.40 (0.0551)681.70 (0.0669)
541.42 (0.0559)691.72 (0.0677)
551.44 (0.0567)701.74 (0.0685)
561.46 (0.0575)181.76 (0.0693)
571.48 (0.0583)191.79 (0.0705)
581.50 (0.0591)201.82 (0.0717)
591.52 (0.0598)211.85 (0.0728)
601.54 (0.0606)221.88 (0.0740)
611.56 (0.0614)±±
HINT:
As a rank of shim thickness is increased (0.020 mm) the preload
of approx. 1.1 N´m (11.2 kgf´cm, 9.7 in.´lbf) is increased accord-
ingly.
12. REMOVE 13 BOLTS, SEPARATE MG1 ASSEMBLY
AND MG2 ASSEMBLY
13. ADJUST SHIM
(a) Install the 2 bearing races and needle roller bearing to the
MG1 assembly.

D09862
D09863
D09864
D09865
D09866
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
HT±33
2001 PRIUS (RM778U)
(b) Install the drive sprocket assembly to the MG1 assembly.
(c) Install the input shaft assembly.
(d) Install the 2 bearing races and needle roller bearing.
(e) Install the planetary ring gear.
(f) Install the ring gear flange.

D09929
Dimension A:
Dimension B:
BA
D09868
HT±34
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
2001 PRIUS (RM778U)
(g) Using a straight edge and vernier calipers, measure the
dimension ºAº and ºBº correctly.
(h) Select a shim that will ensure that the value is within the
specification.
Shim thickness:
Dimension ºBº ± Dimension ºAº
MarkThickness mm (in.)MarkThickness mm (in.)
11.00 (0.0394)72.20 (0.0866)
21.20 (0.0472)82.40 (0.0945)
31.40 (0.0551)92.60 (0.1024)
41.60 (0.0630)102.80 (0.1102)
51.80 (0.0709)113.00 (0.1181)
62.00 (0.0787)123.20 (0.1260)
(i) Install the counter drive gear assembly to the MG1 as-
sembly.

D09930
Dimension A:
A
Dimension B:
B
D09871
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
HT±35
2001 PRIUS (RM778U)
(j) Using a straight edge and vernier calipers, measure the
dimension ºAº and ºBº correctly.
(k) Select a shim thickness is surely within the specified
range.
Shim thickness:
Dimension ºBº ± Dimension ºAº
MarkThickness mm (in.)MarkThickness mm (in.)
A1.35 (0.0531)G1.65 (0.0650)
B1.40 (0.0551)H1.70 (0.0669)
C1.45 (0.0571)J1.75 (0.0689)
D1.50 (0.0591)K1.80 (0.0709)
E1.55 (0.0610)L1.85 (0.0728)
F1.60 (0.0630)±±
14. INSTALL INPUT SHAFT ASSEMBLY TO MG2 AS-
SEMBLY
(a) Install the shim selected in step 13 (h).

D09872
D09873
D09874
D09875
D09876Mark Plate
HT±36
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
2001 PRIUS (RM778U)
(b) Install the ring gear flange.
(c) Install the 2 races and thrust bearing.
HINT:
Apply ATF to the thrust bearing.
(d) Install the planetary ring gear.
(e) Install the input shaft assembly.
15. INSTALL COUNTER DRIVE GEAR ASSEMBLY, CHAIN
AND DRIVE SPROCKET ASSEMBLY
(a) Install the shim selected in step 13 (k).
(b) Install the counter drive gear assembly and chain at the
same time.
NOTICE:
Install the chain with the mark plate facing up.

D09877
D09878
D09879
D09742
D09931
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
HT±37
2001 PRIUS (RM778U)
(c) Put the chain on the drive sprocket and install them.
HINT:
Apply ATF to the drive sprocket needle roller bearing.
(d) Install the 2 bearing races and needle roller bearing.
HINT:
Apply ATF to the thrust bearing.
16. INSTALL PARKING LOCK PAWL TO MG1 ASSEMBLY
(a) Install the lock sleeve.
(b) Install the cam guide sleeve to the sleeve bracket.
(c) Install the cam guide sleeve, sleeve bracket, torsion
spring and 2 bolts.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)