2003 Toyota PriusFACTORY OEM SERVICE PROCEDURE

Input Shaft: Inspection

  1. INSPECT BUSH OF SUN GEAR (MG1 SIDE) 
    1. Using a dial indicator, measure the inside diameter of the bush.

      Standard diameter:  25.525 - 25.546 mm (1.00492 - 1.00575 in.)

      Maximum diameter:  25.596 mm (1.00771 in.)

    2. Visually check and make sure that burnt spots and scratches are not identified.

      If the inside diameter exceeds the limit, replace the sun gear assembly.

      Fig 1: Measuring Inside Diameter Of Bush Using Dial Indicator
      G03431220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT BUSH OF SUN GEAR (MG2 SIDE) 
    1. Using a dial indicator, measure the inside diameter of the bush.

      Standard diameter:  25.525 - 25.546 mm (1.00492 - 1.00575 in.)

      Maximum diameter:  25.596 mm (1.00771 in.)

    2. Visually check and make sure that burnt spots and scratches are not identified.

      If the inside diameter exceeds the limit, replace the sun gear assembly.

      Fig 2: Measuring Inside Diameter Of Bush Using Dial Indicator
      G03431221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. CHECK NEEDLE ROLLER BEARING 

    Check that burnt spots, deformation or play due to the wear is not identified.

    If they are identified, replace the needle roller bearing.

    Fig 3: Checking Needle Roller Bearing
    G03431222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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