Toyota Prius: Pb10/pb12 Hybrid Vehicle Transaxle

Toyota Prius (XW60) 2023-2025 Service Manual / Drivetrain / Pa10/pb10/pb12 (hybrid Transmission / Transaxle) / Pb10/pb12 Hybrid Vehicle Transaxle

On-vehicle Inspection
Removal
Installation

On-vehicle Inspection

ON-VEHICLE INSPECTION

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during hybrid vehicle transaxle assembly inspection are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
*: Even when not replacing the part, it is necessary to perform the specified necessary procedures after installation.
Replacement of shift actuator ECU (Shift control actuator assembly)*	Perform actuator position learning	Shift position not correctly changing Shift position indicator not illuminating or displaying the incorrect drive state

NOTICE:

When disconnecting a wire harness of any component connected to the supply power of the integrated capacitor (integration control supply) or when removing the integrated capacitor (integration control supply), make sure to wait 5 minutes or more after turning the ignition switch off for self-diagnosis to complete and the voltage of the integrated capacitor (integration control supply) to discharge.
If the shift control actuator assembly is replaced or removed, make sure to perform actuator position learning.
If not performed after replacing the shift control actuator assembly, a malfunction such as the shift position not correctly changing, the shift position indicator not illuminating or displaying the incorrect drive state, etc. may occur.
When the shift control actuator assembly is replaced or removed, although the displayed value of Data List item "ACT Position Learning Complete Status" may be "Complete" based on information from before removal, make sure to perform actuator position learning.
When any of the above procedures are completed, change the shift position to all positions and check the following items:
- The shift position indicator illuminates in accordance with the current position.
- The Toyota Prius vehicle does not move when in shift state P (parking brake released)
- The vehicle does not drive when in shift state N
- The vehicle drives when in shift state D or R

PROCEDURE

1. SECURE VEHICLE

(a) Fully apply the parking brake and chock a wheel.

CAUTION:

Make sure to apply the parking brake and chock a wheel before performing this procedure.
If the Toyota Prius vehicle is not secure and the shift lever is moved to N, the vehicle may suddenly move, possibly resulting in an accident or serious injury.

2. REMOVE SHIFT CONTROL ACTUATOR ASSEMBLY

HINT:

Click here

3. INSPECT HYBRID Toyota Prius Vehicle TRANSAXLE ASSEMBLY

(a) Using a pair of pliers, grip the spline portion (*b) of the parking lock shaft that has been wrapped with a cloth or other material and rotate it in the direction shown by the arrow in the illustration.

Standard:

The parking lock smoothly engages and disengages.

NOTICE:

Do not grip the 2-flats portion (*a) of the parking lock shaft.
Make sure to use a cloth or other material to prevent damage to the spline portion (*b) of the parking lock shaft.
After performing the inspection, set the parking lock shaft to the parking lock position.

*a	2-flats Portion of Parking Lock Shaft
*b	Spline Portion of Parking Lock Shaft
*c	Parking Lock
*d	Unlock
*e	Rotate Approximately 20°

4. INSTALL SHIFT CONTROL ACTUATOR ASSEMBLY

HINT:

Click here

Removal

REMOVAL

CAUTION / NOTICE / HINT

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
1: Also necessary after performing a tire rotation. 2: It is not necessary to perform this procedure if the tire pressure warning valve and transmitters are installed to the same location. 3: Even when not replacing the part, it is necessary to perform the specified necessary procedures after installation. 4: The Toyota Prius vehicle height changes because of tire replacement. *5: If matchmarks were not placed when removing parts related to steering operation, perform end position initial setting.
Replacement of ECM	Update ECU security key	Toyota Prius Vehicle Control History (RoB) are stored
	ECU configuration	-
	Perform Toyota Prius Vehicle Identification Number (VIN) registration	DTC is output
Replacement of inverter with converter assembly	ECU configuration	-
Replacement of inverter with converter assembly	Resolver learning	DTCs are stored Slight vibration at a Toyota Prius vehicle speed of 5 km/h (3 mph) or less Shock or vibration during acceleration	for M20A-FXS HEV model: for M20A-FXS PHEV Model:
for PHEV Model: Service Plug Grip	High voltage fuse accumulated load history reset	DTCs are stored
Replacement of hybrid Toyota Prius vehicle transaxle assembly	Resolver learning Initialize resolver	DTCs are stored Slight vibration at a vehicle speed of 5 km/h (3 mph) or less Shock or vibration during acceleration	for M20A-FXS HEV model: for M20A-FXS PHEV Model:
Replacement of engine assembly Gas leak from exhaust system is repaired	Inspection after repair	Poor idle, etc. Engine start function, etc.
Suspension parts	Rear television camera assembly optical axis (Back camera position setting)	Parking Assist Monitor System
	Parking assist ECU initialization	Panoramic View Monitor System
	Parking assist ECU initialization	Advanced Park
Front wheel alignment adjustment	Perform "Calibration"	DTCs are stored ABS warning light illuminates Brake system warning light (yellow indicator) illuminates Slip indicator light illuminates Electronically controlled brake system disabled or malfunctions
Tires	Initialization12 Tire Position Identification12	Tire Pressure Warning System	Refer to Procedures Necessary When Replacing Parts (for Tire Pressure Warning System) table below
	Rear television camera assembly optical axis (Back camera position setting)*4	Parking Assist Monitor System
	Parking assist ECU initialization*4	Panoramic View Monitor System
	Parking assist ECU initialization*4	Advanced Park
Replacement of front bumper assembly*3	Front television camera view adjustment	Panoramic View Monitor System
Replacement of front bumper assembly*3	Front television camera view adjustment	Advanced Park
No. 2 steering intermediate shaft assembly*5	End position initial setting	-

CAUTION:

Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.
- for M20A-FXS HEV Model:
  Click here
- for M20A-FXS PHEV Model:
  Click here
To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.
To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.
The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop or the engine assembly with transaxle may fall off the engine lifter.

*a

An Object Exceeding Weight Limit of Engine Lifter

HINT:

When the cable is disconnected / reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

Learning completes when Toyota Prius vehicle is driven

Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
Front Camera System	Drive the Toyota Prius vehicle straight ahead at 35 km/h (22 mph) or more for 5 seconds or more.

Learning completes when vehicle is operated normally

Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
1: w/o Power Back Door System 2: w/ Power Back Door System
Power Door Lock Control System*1 Back door opener	Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch.
Power Back Door System*2	Reset back door close position
Air Conditioning System	for HEV Model: After the ignition switch is turned to ON, the servo motor standard position is recognized. for PHEV Model: After the ignition switch is turned to ON, the servo motor and expansion valve standard position is recognized.	-

CAUTION / NOTICE / HINT

COMPONENTS (REMOVAL)

Procedure		Part Name Code
1	PERFORM RESOLVER INITIALIZATION	-	-	-
2	ENGINE ASSEMBLY WITH TRANSAXLE	-	-	-	-
3	ENGINE HANGERS	-		-	-
4	OUTLET NO. 1 INVERTER COOLING HOSE	G922C	-	-	-
5	ENGINE WIRE	82121		-	-
6	STARTER HOLE INSULATOR	28193	-	-	-
7	FLYWHEEL HOUSING SIDE COVER	11363A	-	-	-

N*m (kgf*cm, ft.*lbf): Specified torque

●

Non-reusable part

Procedure		Part Name Code
8	ENGINE ASSEMBLY	-		-	-
9	FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY	51201	-	-	-
10	NO. 2 ENGINE MOVING CONTROL ROD	12364B	-	-	-

Procedure		Part Name Code
11	TERMINAL CAP	82823M		-	-
12	MOTOR CABLE	G1148		-	-

Procedure		Part Name Code
13	WIRE HARNESS CLAMP BRACKET	-	-	-	-
14	NO. 1 WATER HOSE CLAMP BRACKET	16575C	-	-	-
15	STUD BOLT	-		-	-
16	TRANSAXLE HOUSING PLUG	-	-	-	-
17	TRANSAXLE BREATHER PLUG	30900N	-	-	-

●

Non-reusable part

★

Precoated part

PROCEDURE

1. PERFORM RESOLVER INITIALIZATION

NOTICE:

If it is necessary to replace the hybrid Toyota Prius vehicle transaxle assembly, make sure to perform resolver initialization before starting work.

Click here

2. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

for HEV Model: Click here
for PHEV Model: Click here

3. INSTALL ENGINE HANGERS

for HEV Model: Click here
for PHEV Model: Click here

4. REMOVE OUTLET NO. 1 INVERTER COOLING HOSE

5. DISCONNECT ENGINE WIRE

NOTICE:

Cover the hole where the shift control actuator assembly was installed with tape or equivalent (non-residue type) to prevent entry of foreign matter, water, etc.

6. REMOVE STARTER HOLE INSULATOR

7. REMOVE FLYWHEEL HOUSING SIDE COVER

8. REMOVE ENGINE ASSEMBLY

NOTICE:

To avoid damaging the knock pins, do not pry between the hybrid Toyota Prius vehicle transaxle assembly and engine assembly.
To prevent the splines of the transmission input damper assembly from becoming misaligned, do not allow the hybrid vehicle transaxle assembly to hit the transmission input damper assembly during engine assembly removal and installation.

9. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

10. REMOVE NO. 2 ENGINE MOVING CONTROL ROD

11. REMOVE TERMINAL CAP

Click here

12. REMOVE MOTOR CABLE

Click here

13. REMOVE WIRE HARNESS CLAMP BRACKET

14. REMOVE NO. 1 WATER HOSE CLAMP BRACKET

15. REMOVE STUD BOLT

(1) Using an E10 "TORX" socket wrench, remove the 2 stud bolts from the hybrid Toyota Prius vehicle transaxle assembly.

16. REMOVE TRANSAXLE HOUSING PLUG

17. REMOVE TRANSAXLE BREATHER PLUG

HINT:

Perform this procedure only when replacement of the transaxle breather plug is necessary.

Installation

INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

The engine assembly with hybrid vehicle transaxle assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop.

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure		Part Name Code
1	TRANSAXLE BREATHER PLUG	30900N	-	-	-
2	TRANSAXLE HOUSING PLUG	-	-	-	-
3	STUD BOLT	-		-	-
4	NO. 1 WATER HOSE CLAMP BRACKET	16575C	-	-	-
5	WIRE HARNESS CLAMP BRACKET	-	-	-	-

	Nm (kgfcm, ft.*lbf): Specified torque	●	Non-reusable part
	Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent	★	Precoated part

Procedure		Part Name Code
6	MOTOR CABLE	G1148		-	-
7	TERMINAL CAP	82823M		-	-

Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)

N*m (kgf*cm, ft.*lbf): Specified torque

Procedure		Part Name Code
8	NO. 2 ENGINE MOVING CONTROL ROD	12364B		-	-
9	FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY	51201	-	-	-
10	ENGINE ASSEMBLY	-		-	-

N*m (kgf*cm, ft.*lbf): Specified torque

Procedure		Part Name Code
11	FLYWHEEL HOUSING SIDE COVER	11363A	-	-	-
12	STARTER HOLE INSULATOR	28193	-	-	-
13	ENGINE WIRE	82121	-	-	-
14	OUTLET NO. 1 INVERTER COOLING HOSE	G922C		-	-
15	ENGINE HANGERS	-	-	-	-
16	ENGINE ASSEMBLY WITH TRANSAXLE	-	-	-	-
17	PERFORM RESOLVER LEARNING	-	-	-

N*m (kgf*cm, ft.*lbf): Specified torque

●

Non-reusable part

PROCEDURE

1. INSTALL TRANSAXLE BREATHER PLUG

HINT:

Perform this procedure only when replacement of the transaxle breather plug is necessary.

Torque:

11.3 N·m {115 kgf·cm, 8 ft·lbf}

2. INSTALL TRANSAXLE HOUSING PLUG

Torque:

39.2 N·m {400 kgf·cm, 29 ft·lbf}

3. INSTALL STUD BOLT

(1) Apply adhesive to the 2 stud bolts.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

NOTICE:

Make sure to install the 2 stud bolts immediately after applying adhesive to prevent foreign matter from attaching to them.

(2) Using an E10 "TORX" socket wrench, install the 2 stud bolts to the hybrid Toyota Prius vehicle transaxle assembly.

Torque:

30 N·m {306 kgf·cm, 22 ft·lbf}

4. INSTALL NO. 1 WATER HOSE CLAMP BRACKET

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

5. INSTALL WIRE HARNESS CLAMP BRACKET

Torque:

20 N·m {204 kgf·cm, 15 ft·lbf}

6. INSTALL MOTOR CABLE

Click here

7. INSTALL TERMINAL CAP

Click here

8. INSTALL NO. 2 ENGINE MOVING CONTROL ROD

Temporarily Tighten

(1) Install the No. 2 engine moving control rod to the hybrid Toyota Prius vehicle transaxle assembly with the 5 bolts in the order shown in the illustration.

Torque:

44 N·m {449 kgf·cm, 32 ft·lbf}

9. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

Torque:

170 N·m {1734 kgf·cm, 125 ft·lbf}

10. INSTALL ENGINE ASSEMBLY

Knock Pin

(1) Make sure that the knock pins are installed to the engine assembly.

(2) Align the knock pins with the holes in the hybrid transaxle assembly and, while keeping the contact surfaces of the engine assembly and hybrid Toyota Prius vehicle transaxle assembly in close contact with one another, temporarily install the bolt (A).

NOTICE:

When tightening the bolts, be sure that the contact surfaces of the engine assembly and hybrid vehicle transaxle assembly are in close contact with one another.
Do not apply grease to the inner splines of the transmission input damper assembly or input shaft assembly.
Make sure that the wire harness or similar items are not pinched between the contact surfaces.
Do not use excessive force when installing the engine assembly.
Make sure to align the hybrid Toyota Prius vehicle transaxle assembly so that the input shaft assembly of the hybrid vehicle transaxle assembly will be inserted straight into the inner splines of the transmission input damper assembly.
When inserting the input shaft assembly of the hybrid vehicle transaxle assembly into the inner splines of the transmission input damper assembly, do not shake the engine assembly excessively.
When installing the engine assembly to the hybrid Toyota Prius vehicle transaxle assembly, make sure to securely fit the knock pins into the knock pin holes.

(3) While keeping the contact surfaces of the engine assembly and hybrid vehicle transaxle assembly in close contact with one another, install the 8 bolts.

Bolt	Bolt Length	Torque
(A), (B)	50 mm (1.97 in.)	64 Nm (653 kgfcm, 47 ft.*lbf)
(C)	35 mm (1.38 in.)	25 Nm (255 kgfcm, 18 ft.*lbf)
(D)	45 mm (1.77 in.)	46 Nm (469 kgfcm, 34 ft.*lbf)

11. INSTALL FLYWHEEL HOUSING SIDE COVER

12. INSTALL STARTER HOLE INSULATOR

Torque:

46 N·m {469 kgf·cm, 34 ft·lbf}

13. CONNECT ENGINE WIRE

Torque:

Bolt (A) :

13 N·m {133 kgf·cm, 10 ft·lbf}

Bolt (B) :

20 N·m {204 kgf·cm, 15 ft·lbf}

14. INSTALL OUTLET NO. 1 INVERTER COOLING HOSE

*A	for PB10	*B	for PB12
*a	2 to 11 mm (0.0787 to 0.433 in.)	*b	Paint Mark
*c	115° (Claw of Clip Location)	*d	275° (Claw of Clip Location)
*e	180° (Claw of Clip Location)	-	-

(1) Install the outlet No. 1 inverter cooling hose to the motor cooling cooler and slide the clip to secure it.

NOTICE:

Make sure to slide the outlet No. 1 inverter cooling hose until it contacts the hose stopper of the motor cooling cooler.
Make sure to align the paint mark of the outlet No. 1 inverter cooling hose with the paint mark of the motor cooling cooler.
Make sure that the claws of the clip are within the location shown in the illustration.

15. REMOVE ENGINE HANGERS

16. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE