Catastrophic motor/generator failure? Pulsating noise under heavy acceleration followed by death

The position sensor isn't embedded near the stator where you suspect rubbing; it's on the end of the shaft (in the end plate for MG2, less accessible inside the transmission for MG1). If you search around (use the term 'resolver' rather than 'position sensor'), you should be able to find some pictures and videos that show where.

I would look carefully at the wiring and connectors before drawing dire conclusions about stuff that's well-protected inside the tranny. A bad connection in the wiring to the resolver is more than enough to throw things off.

You have several other codes that could be brought on by wiring problems too (in different circuits). Is it possible rodents are involved? They sometimes disregard the color codes and chew on circuits that aren't closely related.

The resolver signal is very critical to keeping the magnetic fields in the MG synchronized to the rotor position, and a pulsating noise wouldn't surprise me if that synch was off (though I more expect the ECU to simply say "bad resolver signal, I can't do this" than to try to muddle through).

While looking at the electrical connections to the resolver is fair game, avoid loosening any of the bolts used to adjust it. The adjustment at the factory is critical, and there are no published instructions for doing it in the field.

Another issue that can cause a pulsating noise is a short in a stator winding. The rotor uses permanent magnets, and if there is a shorted loop in a winding, current will always be induced there as the rotor poles go by; nothing can stop it. That would be another condition requiring replacement, but for a different reason than bearing wear.

 

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Sometimes (as in the rodent case), there just isn't a common denominator, though.

 

The symptoms you're describing isn't a failing motor generator, but the car going into safe mode to protect itself from something going wrong in the hybrid system.

Furthermore, because you failed to spend a couple hundred dollars and less than 2 hours of work replacing your clogged catalytic converter your flange gasket failed where cat connects to exhaust header which has been blowing hot exhaust gas into your engine compartment which not only makes a huge mess but starts melting electronic parts. I replaced a valve cover gasket for someone who thought they could ignore their clogged cat that blew out the flange gasket once. It was a huge nasty mess and entirely his fault for failing to repair a simple problem before it turned into a more major problem.