1) Preparation & safety
- Tools & documents: obtain the GH1H workshop manual (torques, clearances, fluid type), transmission jack, engine support, bearing puller/press, dial indicator, micrometers, plastigage, torque wrench.
- Safety: disconnect battery, use proper jacks/supports, wear PPE.
- Theory: correct tools and reference values are required to control tolerances (preload, endplay, backlash). Improper support or hurried disassembly causes secondary damage and misalignment.

2) System-level diagnosis (before removal)
- Symptoms and likely causes (how to confirm):
- Grinding on shift or inability to engage a gear → worn/damaged synchro rings, dog teeth, or worn shift fork/rail misalignment. Confirm by noting which gear(s) affected, listening, and checking shift lever free play and linkage.
- Gear pop-out or slipping out of gear under load → worn dog teeth, bent shift fork, worn shift detent/springs, or worn selector mechanism.
- Loud whining from drivetrain at particular speeds → worn/damaged bearings (input, lay/countershaft, output) or gear tooth wear/backlash incorrect.
- Slippage with poor drive/odd clutch feel → clutch, not transmission (check clutch first); if automatic, check torque converter and clutches/valve body.
- Fluid leakage → seals/gaskets or cracked case.
- Theory: isolate transmission vs clutch/driveline/external linkages. Many “transmission” noises originate in bearings, misalignment or external components.

3) Removal (in order)
- Steps (high level): drain fluid → mark/label linkage & electrical connectors → remove driveshaft/prop shaft → disconnect shift linkage & speedometer cable → remove starter & obstructing components → support engine/transmission → unbolt crossmember and bellhousing bolts → lower transmission with jack.
- Theory: draining prevents spillage, labelling avoids reassembly errors; supporting prevents torsional loading that bends shafts or ruins pilot bearing alignment.

4) Disassembly (order & inspection points)
- External components off first: PTO covers, inspection covers, shift linkage, sensors.
- Split case: remove bolts, separate housings carefully. Note and mark relative positions of mating surfaces.
- Remove shift rails/forks/selector mechanism next (inspect forks for wear, cracks, bend).
- Remove mainshaft, layshaft/countershaft assemblies and bearings. Press off bearings and gears as needed.
- Inspect and measure:
- Gears: tooth profile, pitting, spalling, scoring, chipped dogs, gear face wear.
- Synchronizers: friction ring chamfers, brass/steel wear, broken keys.
- Bearings: radial play, roughness, noise when spun.
- Shafts: spline wear, scoring, straightness (runout), endfloat surfaces.
- Case bore wear, dowel/boss condition.
- Theory: constant-mesh transmissions rely on correct gear geometry, bearing preload and axial clearance. Wear changes contact pattern, increases backlash, noise and load concentration causing accelerated failure.

5) Measurement & decision criteria
- Use dial indicator for shaft endfloat and gear backlash; micrometer for shaft journal diameters; plastigage for bearing clearances. Compare to manual limits.
- Theory: bearings require correct preload; too loose → noise and movement; too tight → overheating/failure. Backlash out of spec → noise and broken teeth. Endfloat too large → mis-meshing and wear.

6) Repair actions and why they fix the fault (common repairs)
- Replace worn/damaged synchronizer rings and keys:
- Theory/fix: synchronizers create friction to match gear speeds for smooth engagement. Worn rings reduce friction, cause grinding and missed shifts. New rings restore friction surface and chamfer geometry so sliding sleeve can engage without clash.
- Replace chipped/broken dog teeth or severely worn gears:
- Theory/fix: broken dogs prevent positive engagement or cause gear pop-out and shock loads. Replacing restores positive engagement geometry and load capacity.
- Replace bearings, races, bushings:
- Theory/fix: worn bearings allow axial/radial play causing noise, misalignment, excessive backlash and gear tooth wear. New bearings restore concentricity and proper preload so loads distribute across gear faces.
- Replace or straighten bent shift forks/rails, renew detents:
- Theory/fix: bent forks misposition sleeves leading to partial engagement or pop-out. Repaired forks restore correct sleeve travel and alignment.
- Re-machine or replace shafts if scored or bent:
- Theory/fix: a damaged journal or spline causes bearing misfit or clutch spline slip; replacement restores true running and correct bearing press fit.
- Replace seals/gaskets and correct case sealing:
- Theory/fix: eliminates leakage that can starve bearings/clutches of lubricant — preventing overheating and metal fatigue.
- Replace speedometer gears/PTO components as required.
- Case repair: weld/rebuild boss areas only if within manual allowances and re-bore to spec, otherwise replace.
- If automatic: clean valve body, replace clutch packs, seals, solenoids or torque converter as indicated. Theory: hydraulic control and friction elements must function to transmit torque properly.

7) Reassembly (correct order and controls)
- Fit shafts, bearings, gears in recommended sequence from manual, set bearing preloads and endfloats with shims where required. Install synchronizers, shafts, shift forks, selector assemblies, then close housings, torque bolts to spec. Fit new seals/gaskets.
- Check gear backlash and runout as you assemble; adjust shims/preloads to spec.
- Theory: reassembly with correct preload/backlash ensures correct gear mesh geometry, even load distribution and long life. Torque sequences control case distortion.

8) Fill, bench and road testing
- Add correct fluid to spec and temperature-based fill level if required.
- Bench test: shift through all gears with transmission supported to verify detent function and positive selection. Check output rotation under input with low speed.
- Road test under varied loads, note noise/temperature/leaks. Re-check fasteners, fluid level, and shift quality after initial run.
- Theory: fluid restores lubrication/cooling; dynamic testing under load verifies that clearances and reassembly tolerances behave correctly in service conditions.

9) Common symptom → fix mapping (concise)
- Grinding on upshifts/downshifts → replace worn synchronizers and possibly clutch if slipping; ensures speed matching and friction surface.
- Gear jump-out under load → replace dog teeth/shift forks/detents; restores positive mechanical engagement.
- Low-speed whine that changes with engine speed → worn input or countershaft bearings; replace bearings to re-center shafts and restore proper gear meshing.
- Oil leak at input/output → replace seal(s) and check shaft runout; stops lubricant loss that would damage bearings and gears.
- Hard/slow shifting → linkages, worn synchronizers, or excessive backlash; restore linkage adjustment and replace synchronizers as needed.

10) Final notes
- Always use OEM parts or equivalent for gears/synchros/bearings. Use specified fluid and torques.
- Do not reuse damaged bearings, sync rings or seals. Small savings replaceable parts can cause big failures if ignored.
- Refer to the GH1H workshop manual for exact torque, shim patterns, clearance and break-in procedures.

This is the ordered theory + repair mapping; follow the workshop manual values for measurements, torques and specific assembly sequences.
rteeqp73

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