I got a call that the parts arrived and they have the transmission/motor and REx down . . .
Here we see the rest of the bolt in the transmission/motor mount. You can clearly see there was a rocking motion that just like a coat hanger wire, flexed and broke the bolt.
The new mount frame is substantially larger, a solid aluminum piece:
Notice the "U" shaped channel so instead of putting all the stress on the bolt, the shoulders of the "U" will transmit the forces to a much larger area.
Here are the two new bolts and the remaining bolt from the engine side:
Substantially larger, the new bolts will be substantially stronger. If I remember correctly, the strength increases by the the square of the diameter.
The original bolt had a smooth shoulder which would minimize the stress on the bolt head:
However, the stresses deformed the bolt attachment piece enough to lead to vibration and fracture in the threaded part, narrowest part of the bolt. In contrast, the new bolt is substantially larger and threaded the whole length.
There is a new mount piece on the engine side:
Again, substantially larger piece with the "U" shaped shoulders to take up the stress. It has to be "U" shaped as the engine is raised to fit into the body/frame pieces.
The part that came from Germany was the air conditioner (AC) hose:
When the mount failed, everything dropped and the refrigerant hose broke . . . and leaked it out. So part of the repair, after the hose replacement, is to draw a vacuum and recharge the AC. Had the repair been done under a recall, the refrigerant leak would not have happened and replacement hose would not have been needed.
From the rear, here is the transmission/motor assembly and REx:
Draped in the foreground is the cabling to the tail lights. I have a 2" receiver hitch but it has no lights. To add lights, I'll need a 12V power, 'relay' box that amplifies the light signals to generate the typically much higher drawing trailer lights.
Finally, here is a neat shot of the 5-point attachment holding the wheels:
Truly brilliant, these five, links with rubberized bushings hold the wheels semi-rigid and aligned. Yes, there will be small displacements from bumps and normal operation but the 5-points bring the wheels back into alignment.
Final repairs and assembly are in progress and I told the tech,"Take your time and do it right. I have my Prius which is working perfectly fine."
On the way out, I suggested the service writers and staff take a minute or two to see what the repairs look like. I got the impression this is the first one in this area.