Removal And Installation

REDUCTION GEAR

Removal and Installation


WARNING:
- Because hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are handled incorrectly. Be sure to follow the correct work procedures when performing inspection and maintenance.
- Be sure to remove the service plug in order to disconnect the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.
- To prevent the removed service plug from being connected by mistake during the procedure, always carry it in your pocket or put it in the tool box.
- Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses before beginning work on the high voltage system.
- Clearly identify the persons responsible for high voltage work and ensure that other persons do not touch the vehicle. When not working, cover high voltage parts with an insulating cover sheet or similar item to prevent other persons from contacting them.
- High Voltage Precautions.

CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do so in the Service Manual.

REMOVAL


WARNING:
Disconnect high voltage. Service and Repair.
1.Check voltage in high voltage circuit. (Check that condenser are discharged.)
a.Lift up the vehicle and remove Li-ion battery under covers. Service and Repair.
b.Disconnect high voltage harness connector from front side of Li-ion battery. Service and Repair.
c.Measure voltage between high voltage harness connector terminals.











CAUTION:
For voltage measurements, use a tester which can measure to 500 V or higher.
2.Drain coolant from radiator. Coolant Draining And Refilling.
3.Remove traction motor inverter. Removal And Installation.
4.Drain reduction gear oil from reduction gear. Draining And Refilling.
5.Remove traction motor and reduction gear from vehicle together as suspension member assembly. Removal And Installation.
6.Remove right and left front drive shafts. Removal And Installation Right Side (RH)
and Removal And Installation Left Side (LH).
7.Install motor slinger onto traction motor, then lift traction motor with hoist to hold the position of traction motor.
NOTE:
The traction motor does not become displaced when motor mounting and motor mounting bracket are removed.





















8.Remove motor mounting rear bracket.










9.Remove motor mounting LH bracket.





10.Remove bolts fixing traction motor and reduction gear, then remove reduction gear.











INSTALLATION

Note the following, and install in the reverse order of removal.





CAUTION:
- Be sure to reinstall high voltage harness clips in their original positions. If a clip is damaged, replace it with a new clip before installing.
- Be sure to perform correct air bleeding after adding coolant. Coolant Draining And Refilling.
- Before installing reduction gear to traction motor, apply recommended grease to full periphery of shaft spline (A). Inject recommended grease [8.5 g (0.3 oz) min., 20 g (0.7 oz) max.] into inner part of reduction gear input shaft spline (B). Do not damage O-ring (1) when installing reduction gear.






CAUTION:
Clean the grease applying area to remove old grease and abrasion powder before applying grease.
- After all parts are installed, be sure to check equipotential of traction motor, electric compressor, and traction motor inverter.
- Inspection And Adjustment. (Traction motor)
- Electric Compressor Inspection. (Electric compressor)
- Inspection And Adjustment. (Traction motor inverter)