Toyota Prius: Rear Suspension Member (for Awd)

Toyota Prius (XW60) 2023-2025 Service Manual / Suspension / Rear Suspension / Rear Suspension Member (for Awd)

Removal
Installation

Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during rear suspension member sub-assembly removal/installation 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
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: The Toyota Prius vehicle height changes because of suspension or tire replacement.
Rear 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)
	Rear television camera assembly optical axis (Back camera position setting)*3	Parking Assist Monitor System
	Parking assist ECU initialization*3	Panoramic View Monitor System
	Parking assist ECU initialization*3	Advanced Park
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
Gas leak from exhaust system is repaired	Inspection after repair	Poor idle, etc. Engine start function, etc.

CAUTION / NOTICE / HINT

CAUTION:

Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.
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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 pipe or other high temperature components while the engine is hot.

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	TAIL EXHAUST PIPE ASSEMBLY	17430		-	-

●

Non-reusable part

Procedure		Part Name Code
2	SERVICE PLUG GRIP	G3834	-	-	-

Procedure		Part Name Code
3	SHIELD CAP	85247			-
4	FRONT WIPER ARM AND BLADE ASSEMBLY LH	-	-	-	-
5	FRONT WIPER ARM AND BLADE ASSEMBLY RH	-	-	-	-
6	WINDSHIELD LOWER OUTSIDE MOULDING LH	75536D		-	-
7	WINDSHIELD LOWER OUTSIDE MOULDING RH	75535F	-	-	-
8	COWL WATER EXTRACT SHIELD LH	55754F	-	-	-
9	COWL WATER EXTRACT SHIELD RH	55753D	-	-	-
10	COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY	55708	-	-	-
11	CHECK TERMINAL VOLTAGE	-		-	-
12	COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY	55708		-	-
13	COWL WATER EXTRACT SHIELD RH	55753D	-	-	-
14	COWL WATER EXTRACT SHIELD LH	55754F	-	-	-
15	WINDSHIELD LOWER OUTSIDE MOULDING LH	75536D	-	-	-
16	WINDSHIELD LOWER OUTSIDE MOULDING RH	75535F	-	-	-
17	FRONT WIPER ARM AND BLADE ASSEMBLY RH	-		-	-
18	FRONT WIPER ARM AND BLADE ASSEMBLY LH	-	-	-	-
19	SHIELD CAP	85247	-	-	-

*1	Connector Cover Assembly	-	-
	Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping" : Nm (kgfcm, ft.*lbf)		Nm (kgfcm, ft.*lbf): Specified torque

Procedure		Part Name Code
20	DECK BOARD ASSEMBLY	58410B	-	-	-
21	DECK FLOOR BOX RH	64995	-	-	-
22	DECK FLOOR BOX LH	64997	-	-	-
23	REAR TRACTION MOTOR CABLE	G1149		-	-

*A	for Type A	*B	for Type B
*C	w/o Spare Tire	*D	w/ Spare Tire

Procedure		Part Name Code
24	REAR DRIVE SHAFT ASSEMBLY LH	42340B	-	-	-
25	REAR DRIVE SHAFT ASSEMBLY RH	42330	-	-	-

Procedure		Part Name Code
26	REAR UPPER CONTROL ARM ASSEMBLY LH	48790		-	-
27	REAR UPPER CONTROL ARM ASSEMBLY RH	48770A	-	-	-
28	FRAME WIRE	-	-	-	-
29	REAR SUSPENSION MEMBER SUB-ASSEMBLY	51206A		-	-
30	NO. 6 FLOOR WIRE	82169A	-	-	-
31	REAR TRACTION MOTOR CABLE	G1149		-	-

Procedure		Part Name Code
32	REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY	G1050		-	-
33	MOTOR CABLE BRACKET	-	-	-	-
34	WIRE HARNESS CLAMP BRACKET	-	-	-	-
35	REAR UPPER CONTROL ARM ASSEMBLY LH	48790		-	-
36	REAR UPPER CONTROL ARM ASSEMBLY RH	48770A	-	-	-
37	REAR NO. 2 SUSPENSION ARM ASSEMBLY LH	48740F		-	-
38	REAR NO. 2 SUSPENSION ARM ASSEMBLY RH	48730F	-	-	-
39	DIFFERENTIAL MOUNT CUSHION	41651G		-	-

*1	DIFFERENTIAL MASS DAMPER	-
●	Non-reusable part	-	-

PROCEDURE

1. REMOVE TAIL EXHAUST PIPE ASSEMBLY

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2. REMOVE SERVICE PLUG GRIP

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3. REMOVE SHIELD CAP

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4. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH

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5. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH

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6. REMOVE WINDSHIELD LOWER OUTSIDE MOULDING LH

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7. REMOVE WINDSHIELD LOWER OUTSIDE MOULDING RH

(a) Use the same procedure as for the LH side.

8. REMOVE COWL WATER EXTRACT SHIELD LH

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9. REMOVE COWL WATER EXTRACT SHIELD RH

(a) Use the same procedure as for the LH side.

10. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

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11. CHECK TERMINAL VOLTAGE

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12. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

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13. INSTALL COWL WATER EXTRACT SHIELD RH

14. INSTALL COWL WATER EXTRACT SHIELD LH

15. INSTALL WINDSHIELD LOWER OUTSIDE MOULDING LH

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16. INSTALL WINDSHIELD LOWER OUTSIDE MOULDING RH

(a) Use the same procedure as for the LH side.

17. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH

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18. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH

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19. INSTALL SHIELD CAP

20. REMOVE DECK BOARD ASSEMBLY

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21. REMOVE DECK FLOOR BOX RH

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22. REMOVE DECK FLOOR BOX LH

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23. DISCONNECT REAR TRACTION MOTOR CABLE

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24. REMOVE REAR DRIVE SHAFT ASSEMBLY LH

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25. REMOVE REAR DRIVE SHAFT ASSEMBLY RH

(a) Use the same procedure as for the LH side.

26. SEPARATE REAR UPPER CONTROL ARM ASSEMBLY LH

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27. SEPARATE REAR UPPER CONTROL ARM ASSEMBLY RH

(a) Perform the same procedure as for the LH side.

28. SEPARATE FRAME WIRE

29. REMOVE REAR SUSPENSION MEMBER SUB-ASSEMBLY

*a	Engine Lifter	*b	Attachment
	Attachment and Wooden Block Placement Location	-	-

(1) Using an engine lifter and 4 attachments or equivalent tools, support the rear suspension member sub-assembly as shown in the illustration.

CAUTION:

The rear suspension member sub-assembly is a very heavy component. Make sure that it is supported securely.
If the rear suspension member sub-assembly is not securely supported, it may drop, resulting in serious injury.

NOTICE:

Use attachments or equivalent tools to keep the rear suspension member sub-assembly level.

(2) Remove the 2 bolts and 2 nuts.

(3) Slowly lower the rear suspension member sub-assembly.

NOTICE:

When lowering the rear suspension member sub-assembly, be careful not to damage the Toyota Prius vehicle body or other components installed to the vehicle.

30. REMOVE NO. 6 FLOOR WIRE

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31. DISCONNECT REAR TRACTION MOTOR CABLE

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32. REMOVE REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY

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33. REMOVE MOTOR CABLE BRACKET

34. REMOVE WIRE HARNESS CLAMP BRACKET

35. REMOVE REAR UPPER CONTROL ARM ASSEMBLY LH

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36. REMOVE REAR UPPER CONTROL ARM ASSEMBLY RH

(a) Use the same procedure as for the LH side.

37. REMOVE REAR NO. 2 SUSPENSION ARM ASSEMBLY LH

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38. REMOVE REAR NO. 2 SUSPENSION ARM ASSEMBLY RH

39. REMOVE DIFFERENTIAL MOUNT CUSHION

*a	Turn	*b	Hold
	Turning Direction		Front of Toyota Prius Vehicle

(1) Using SST, remove the differential mount cushion from the rear suspension member sub-assembly.

SST: 09570-48010

NOTICE:

Apply grease to the threads of the SST center bolt before use.
Install the SST bolts straight and tighten them equally.

Installation

INSTALLATION

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure		Part Name Code
1	DIFFERENTIAL MOUNT CUSHION	41651G		-	-
2	REAR NO. 2 SUSPENSION ARM ASSEMBLY LH	48740F		-	-
3	REAR NO. 2 SUSPENSION ARM ASSEMBLY RH	48730F	-	-	-
4	REAR UPPER CONTROL ARM ASSEMBLY LH	48790		-	-
5	REAR UPPER CONTROL ARM ASSEMBLY RH	48770A	-	-	-
6	WIRE HARNESS CLAMP BRACKET	-	-	-	-
7	MOTOR CABLE BRACKET	-	-	-	-
8	REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY	G1050		-	-

*1	NO. 2 CAMBER ADJUST CAM	*2	REAR SUSPENSION TOE ADJUST CAM SUB-ASSEMBLY
*3	DIFFERENTIAL MASS DAMPER	-	-
	Nm (kgfcm, ft.*lbf): Specified torque	-	-

Procedure		Part Name Code
9	REAR TRACTION MOTOR CABLE	G1149		-	-
10	NO. 6 FLOOR WIRE	82169A	-	-	-
11	REAR SUSPENSION MEMBER SUB-ASSEMBLY	51206A		-	-
12	FRAME WIRE	-	-	-	-
13	REAR UPPER CONTROL ARM ASSEMBLY LH	48790		-	-
14	REAR UPPER CONTROL ARM ASSEMBLY RH	48770A	-	-	-

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

Procedure		Part Name Code
15	REAR DRIVE SHAFT ASSEMBLY LH	42340B		-	-
16	REAR DRIVE SHAFT ASSEMBLY RH	42330	-	-	-

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

Do not apply lubricants to the threaded parts

Procedure		Part Name Code
17	REAR NO. 1 SUSPENSION ARM ASSEMBLY LH	48720A		-	-
18	REAR NO. 1 SUSPENSION ARM ASSEMBLY RH	48710A	-	-	-
19	REAR LOWER COIL SPRING INSULATOR LH	48258C	-	-	-
20	REAR LOWER COIL SPRING INSULATOR RH	48258B	-	-	-
21	REAR COIL SPRING LH	48231B		-	-
22	REAR COIL SPRING RH	48231A	-	-	-
23	REAR STABILIZER BAR	48812		-	-

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

Procedure		Part Name Code
24	STABILIZE SUSPENSION	-		-	-
25	REAR NO. 1 SUSPENSION ARM ASSEMBLY LH	48720A		-	-
26	REAR NO. 1 SUSPENSION ARM ASSEMBLY RH	48710A	-	-	-
27	REAR NO. 2 SUSPENSION ARM ASSEMBLY LH	48740F		-	-
28	REAR NO. 2 SUSPENSION ARM ASSEMBLY RH	48730F	-	-	-
29	REAR UPPER CONTROL ARM ASSEMBLY LH	48790		-	-
30	REAR UPPER CONTROL ARM ASSEMBLY RH	48770A	-	-	-

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

Procedure		Part Name Code
31	REAR FLEXIBLE HOSE LH	47319F		-	-
32	REAR FLEXIBLE HOSE RH	47318F	-	-	-
33	REAR STABILIZER LINK ASSEMBLY LH	48840A		-	-
34	REAR STABILIZER LINK ASSEMBLY RH	48830D	-	-	-
35	REAR AXLE SHAFT NUT (for LH Side)	42312B		-	-
36	REAR AXLE SHAFT NUT (for RH Side)	42312B	-	-	-
37	REAR SKID CONTROL SENSOR LH	89544E		-	-
38	REAR SKID CONTROL SENSOR RH	89544D	-	-	-

*1	NO. 2 PARKING BRAKE WIRE ASSEMBLY	●	Non-reusable part
	Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping": Nm (kgfcm, ft.*lbf)		Do not apply lubricants to the threaded parts

Procedure		Part Name Code
39	TAIL EXHAUST PIPE ASSEMBLY	17430	-	-	-
40	REAR WHEEL	-	-	-	-

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

●

Non-reusable part

Procedure		Part Name Code
41	REAR SUSPENSION TOE ADJUST CAM SUB-ASSEMBLY (for LH Side)	48409		-	-
42	REAR SUSPENSION TOE ADJUST CAM SUB-ASSEMBLY (for RH Side)	48409	-	-	-

*1	NO. 2 CAMBER ADJUST CAM	-	-
	Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping": Nm (kgfcm, ft.*lbf)	-	-

Procedure		Part Name Code
43	REAR FLOOR SIDE MEMBER COVER LH	57628E	-	-	-
44	REAR FLOOR SIDE MEMBER COVER RH	57627G	-	-	-

Procedure		Part Name Code
45	REAR TRACTION MOTOR CABLE	G1149		-	-
46	DECK FLOOR BOX LH	64997	-	-	-
47	DECK FLOOR BOX RH	64995	-	-	-
48	DECK BOARD ASSEMBLY	58410B	-	-	-

*A	for Type A	*B	for Type B
*C	w/o Spare Tire	*D	w/ Spare Tire

Procedure		Part Name Code
49	SERVICE PLUG GRIP	G3834	-	-	-
50	INSPECT FOR EXHAUST GAS LEAK	-	-	-
51	INSPECT AND ADJUST REAR WHEEL ALIGNMENT	-	-	-
52	PERFORM INITIALIZATION	-	-	-

PROCEDURE

1. INSTALL DIFFERENTIAL MOUNT CUSHION

*a	90° /- 3°	-	-
	Front of Toyota Prius Vehicle	-	-

(1) Temporarily install a new differential mount cushion to the rear suspension member sub-assembly from the rear of the vehicle as shown in the illustration.

NOTICE:

Make sure that the differential mount cushion is aligned within 90° /- 3° from the center.
Be sure to install the differential mount cushion in the correct direction.

*a	-3° to 3°	*b	Hold
*c	Turn	-	-
	Turning Direction		Front of Toyota Prius Vehicle

(1) Using SST, press the differential mount cushion into the rear suspension member sub-assembly. (Step *1)

SST: 09570-48010

NOTICE:

Apply grease to the threads of the SST center bolt before use.
Install the SST bolts straight and tighten them equally.

(1) Using a vernier caliper, measure the length indicated by (A) in the illustration. (Step *2)

NOTICE:

Measure at several points to ensure that the differential mount cushion is pressed in evenly.
Do not measure on a weld bead.

(2) Repeat the steps *1 and *2 to press the differential mount cushion into the rear suspension member sub-assembly until the length indicated by (A) in the illustration is within the specification.

Reference Length (A):

10.5 to 11.5 mm (0.414 to 0.452 in.)

(3) Remove SST. Using a vernier caliper, measure the differential mount cushion protrusion length indicated by (B) in the illustration and ensure that the measured length is within the specification.

Standard Length (B):

4.5 to 5.5 mm (0.178 to 0.216 in.)

2. TEMPORARILY INSTALL REAR NO. 2 SUSPENSION ARM ASSEMBLY LH

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3. TEMPORARILY INSTALL REAR NO. 2 SUSPENSION ARM ASSEMBLY RH

4. INSTALL REAR UPPER CONTROL ARM ASSEMBLY LH

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5. INSTALL REAR UPPER CONTROL ARM ASSEMBLY RH

6. REMOVE WIRE HARNESS CLAMP BRACKET

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

7. INSTALL MOTOR CABLE BRACKET

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

8. INSTALL REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY

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9. CONNECT REAR TRACTION MOTOR CABLE

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10. INSTALL NO. 6 FLOOR WIRE

11. INSTALL REAR SUSPENSION MEMBER SUB-ASSEMBLY

*a	Engine Lifter	*b	Attachment
	Attachment and Wooden Block Placement Location	-	-

(1) Using an engine lifter and 4 attachments or equivalent tools, support the rear suspension member sub-assembly as shown in the illustration.

CAUTION:

The rear suspension member sub-assembly is a very heavy component. Make sure that it is supported securely.
If the rear suspension member sub-assembly is not securely supported, it may drop, resulting in serious injury.

NOTICE:

Use attachments or equivalent tools to keep the rear suspension member sub-assembly level.
Keep supporting the rear suspension member sub-assembly until the installation has been completed.

(2) Raise the rear suspension member sub-assembly until there is no clearance between the rear suspension member sub-assembly and Toyota Prius vehicle.

(3) Install the rear suspension member sub-assembly with the 2 bolts and 2 nuts.

Torque:

143 N·m {1458 kgf·cm, 105 ft·lbf}

12. INSTALL FRAME WIRE

13. TEMPORARILY INSTALL REAR UPPER CONTROL ARM ASSEMBLY LH

(1) Temporarily install the rear upper control arm assembly LH to the rear axle carrier sub-assembly LH with the bolt and nut.

NOTICE:

Insert the bolt with the threaded end facing the rear of the Toyota Prius vehicle.
Because the nut has its own stopper, do not turn the nut. Tighten the bolt with the nut secured.

14. TEMPORARILY INSTALL REAR UPPER CONTROL ARM ASSEMBLY RH

15. INSTALL REAR DRIVE SHAFT ASSEMBLY LH

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