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Hino Truck Super F Series GH1H Workshop Manual download

- Safety first
- Wear safety glasses, gloves, and steel-toe boots; planetary gear removal is heavy and can cause crush or eye injuries.
- Work on a flat surface, chock wheels, disconnect battery, and use rated lifting equipment and axle stands; never rely on a jack alone.
- Have a fire extinguisher and spill kit for gear oil ready.

- Before you start — essential reminders
- Have the Hino Super F Series GH1H official workshop/service manual on hand for exact torque figures, shim thicknesses, clearances, and procedural notes.
- Do not proceed without a torque wrench and a dial indicator; final drive preload and backlash must be set to factory specs.
- If you are a complete beginner and you lack a hydraulic press, gearbox jack or axle lift and the ability to measure and set backlash/preload precisely, this job is best done by a qualified shop.

- High‑level job overview (what you will do)
- Drain final drive oil, remove wheels and brake components as needed, remove axle shafts or hub assemblies, separate final drive housing, extract carrier/planetary assembly, press out bearings/gears, replace worn parts, reassemble with new bearings/seals/shims, set bearing preload and ring gear backlash, refill with specified gear oil, test drive.

- Tools you will need (detailed descriptions and how to use them)
- Basic socket set and ratchets (metric and SAE)
- Use for removing nuts and bolts. Choose sockets that fit snugly—rounded sockets damage fasteners.
- Use breaker bar for initial loosening of large, tight fasteners.
- Torque wrench (click‑type)
- Required to tighten fasteners to manufacturer torque specs. Set correct torque, tighten smoothly until wrench clicks; do not use impact on final torque.
- Impact wrench (air or electric)
- Speeds removal of stubborn bolts; do not use to set final torque on critical fasteners—always finish with torque wrench.
- Breaker bar / cheater bar
- For stubborn bolts. Apply steady force; avoid sudden jerks.
- Hydraulic jack and rated axle stands OR vehicle lift
- Safely raise and support the truck. Use stands rated above the vehicle axle load and place under manufacturer‑recommended lift points.
- Transmission jack / gearbox jack or floor jack with wooden blocks
- To support and lower heavy final drive housing or carrier assemblies safely.
- Hydraulic press (or shop with press)
- For pressing bearings off/on shafts and pressing out bushings. Bearings require controlled, axial force using correct adapters.
- Bearing puller / gear puller
- For removing gears, bearings, sleeves when a press is unavailable. Use even pressure and protect mating surfaces with blocks or drift.
- Heat source (induction heater or hot plate) or bearing heater
- Heating gears or bearings slightly makes pressing on easier without damaging parts; do not use open flame.
- Snap ring (circlip) pliers
- For removing/installing retaining rings. Use correct internal/external type to avoid ring deformation.
- Punches, drifts, brass/nylon mallet
- For tapping components free without marring parts; use brass or nylon to avoid sparks/damage.
- Pry bars and large screwdrivers (use carefully)
- For separating housings or levering components; protect mating surfaces with wooden blocks.
- Dial indicator with magnetic base
- To measure ring gear backlash. Mount base to housing, contact gear tooth flank, rotate and read backlash; crucial for correct mesh.
- Micrometer and/or Vernier caliper
- For measuring bearing journal diameters, gear thickness, and wear limits.
- Feeler gauges / thickness gauges / shim kit
- To measure and set bearing preload and clearance; replacement shims may be required to achieve correct backlash.
- Bearing race and seal driver set
- To install bearings and seals squarely without damage.
- Threadlocker (e.g., Loctite) and anti-seize compound
- Threadlocker for specified bolts; anti-seize for studs or bolts that must be removed later.
- Gear oil pump / fluid transfer pump and collection pan
- To drain and refill heavy gear oil safely; catch oil for proper disposal.
- Cleaning supplies: degreaser, lint‑free rags, brushes
- Clean mating surfaces before assembly; no dirt allowed in bearings.
- Safety equipment: face shield, gloves, hearing protection
- Protect yourself from flying debris and loud impact tools.

- Extra/optional but often required shop tools and why
- Heavy hydraulic press (100+ tons for some heavy truck carriers)
- Pressing large bearings and gears off/on often requires very high forces that hand pullers can’t deliver.
- Induction bearing heater
- Heats bearings uniformly for interference-fit installation; reduces risk of thermal damage and saves time.
- Bearing installer adapters sized for the job
- Prevents damage to bearing race or seal during installation.
- Torque multiplier / large torque wrench
- For very high torque fasteners where standard torque wrenches don’t reach.
- Dial torque wrench for low torque
- Some small fasteners require precise low torque.
- Pressing fixtures for planetary carriers
- Aligns and supports the carrier during press operations.

- Consumable parts to have on hand and why they are usually replaced
- Full planetary gear set (sun gear, planet gears, carrier, ring gear) or at minimum the worn components
- Replace if teeth show pitting, spalling, scoring, or excessive wear. Even if only one part appears worn, matched gear sets are recommended to ensure proper contact patterns.
- Bearings and bearing races (all bearings removed)
- Bearings are high‑load wear items; extraction often damages races and bearings. Replace to ensure preload and long life.
- Seals and O‑rings
- Always replace seals to prevent leaks in reassembled housing.
- Gaskets and RTV sealant
- Replace all gaskets and use proper sealant where specified.
- Shims and thrust washers
- Replace or change to achieve correct backlash and preload; old shims may be crushed or out of spec.
- Ring gear bolts (and locking compound if specified)
- Manufacturer often requires new bolts or specified torque/locking method due to fatigue from previous tightening.
- Gear oil (specified grade and quantity)
- Refill with correct viscosity/EP gear oil per manual.
- Fasteners (nuts/bolts) that are torque-to-yield or corroded
- Replace any that are damaged or specified as one-time use.

- Step‑by‑step procedure (concise, do not skip manual values)
- Prepare vehicle and workspace
- Park on level surface, chock wheels, disconnect battery, lift vehicle and support on stands.
- Drain final drive oil into a suitable container; dispose of fluid per regulations.
- Remove housings and hubs to access planetary assembly
- Remove wheels, brakes, hubnuts, brake backing plates and axle shafts/hubs as needed to expose the final drive housing.
- Label and bag small parts and fasteners; photograph orientation for reassembly.
- Separate final drive housing
- Support heavy housing with transmission/gear jack and remove housing bolts. Ease housing free with pry bars while supporting assembly weight.
- Remove carrier assembly
- Mark relation of ring gear and carrier orientation for reassembly.
- Remove ring gear bolts (impact for removal, tighten with torque wrench during reassembly).
- Extract carrier/planetary assembly with jack or crane if heavy.
- Disassemble planetary unit
- Secure carrier in press or on bench. Remove snap rings, planet pins, and press out planet gears and sun gear as required.
- Recover shims and note their positions and orientation.
- Inspect all components
- Check gear teeth for chipped/pitted surfaces, spalling, discoloration or scoring.
- Measure bearings, journals, gear tooth thickness and tooth contact pattern against specs in the manual.
- Inspect bearing races and cups for wear; if in doubt, replace.
- Decide what to replace
- Replace any gear with visible pitting, chipped teeth or excessive wear.
- Replace all bearings and seals as a matter of course.
- Replace shims if out of tolerance; have a shim pack available to achieve correct preload/backlash.
- Replace ring gear bolts and any corroded fasteners.
- Press-on installation and reconditioning
- Heat ring gear/bearing as recommended or use press. Install bearings with proper drivers and apply specified press force evenly.
- Install planet gears, pins, thrust washers and snap rings exactly as removed.
- Set bearing preload and backlash
- Use dial indicator to measure ring gear backlash; adjust shims until the measured backlash matches the factory spec.
- Set bearing preload using torque-on-rotation method or by measuring torque per manual; this requires a torque wrench and sometimes a torque multiplier. Preload often requires installing correct inner/outer shims.
- Confirm gear tooth contact pattern with marking compound or Prussian blue; adjust if contact pattern is incorrect.
- Final assembly
- Clean all mating surfaces; fit new gaskets/seals, apply threadlocker where specified, and torque all fasteners to factory values.
- Reinstall housing, reassemble hubs/brakes/wheels, and refill with correct gear oil.
- Test
- Lower vehicle, reconnect battery, run engine and operate drive to circulate oil; check for leaks.
- Road test at low speeds first; listen for abnormal noise, check for oil leaks, and re-check torque on accessible fasteners after initial run-in per manual.

- Common pitfalls and warnings
- Do not guess preload/backlash values—incorrect settings will destroy the gearset quickly.
- Never reuse bearings and seals removed from the carrier; they are relatively inexpensive compared to catastrophic failure.
- Avoid using a torch to heat bearings or gears directly; use induction or oil bath methods as specified.
- Ensure cleanliness—dirt or metal chips kill bearings fast.
- Document shim pack removal order and measure everything; reassembly without measuring leads to failure.

- Quick checklist of replacement parts to order before starting
- Full planetary gear set or individual planet/sun/ring gear if available
- Full bearing kit (all bearings and races for the final drive)
- Seals, gaskets, O‑rings for the housing
- Shim set or assorted shims per manual range
- Ring gear bolts (and threadlocker if required)
- Specified gear oil (quantity per manual)
- Any hub/axle studs or nuts that are worn or torque‑to‑yield

- Final note (short and essential)
- This job requires precision measurement and heavy‑duty tools. If you do not have a press, dial indicator, torque multiplier and the workshop manual, do not proceed—hire a professional shop.
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