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Hino Truck Super F Series GH1H Workshop Manual download

1) Fault, causes and theory (short)
- Symptom: clunks, rattles, excessive chassis movement, rapid wear of shocks, uneven ride, looseness at mounting points.
- Root causes: rubber/urethane bushing deterioration (cracking, extrusion), corrosion of bolt/stud, bolt elongation or shearing, bracket fatigue/cracking, seized component causing lateral loads.
- How repair fixes it: restores correct load path and damping geometry so the shock transmits vertical loads into the chassis through a stiff, correctly located mount rather than through worn elastic material or a loose joint. Replacing bushings/brackets removes play, restores pre-load and alignment of the damper, stops fretting/cyclic bending at cracks, and re-establishes predictable energy dissipation by the shock.

2) Tools, parts & safety (prepare)
- Parts: correct replacement shock-mount bushings (OEM spec), washers/spacers, bolts/studs/nuts (replace hardware), shock absorber if damaged, replacement bracket/weld plate if bracket cracked.
- Tools: jack and axle stands or heavy-duty lift, blocks/chocks, hydraulic jack for axle support, penetrating fluid, hammer/soft mallet, socket/set, breaker bar, impact gun if used carefully, press or bushing driver, grinder/cut-off for seized studs, welding kit and matching filler if bracket replacement, torque wrench, feeler gauges, service manual for torque/specs.
- PPE: eye protection, gloves, welding PPE.
- Safety notes: support vehicle so no unintended movement; support axle so springs/leafs are held at ride height (avoid removing shock under full preload or letting suspension hang uncontrolled).

3) Inspection (measure & decide)
- Visual: check bushings for cracks/extrusion, measure free play at joint by prying, look for rust, elongation, deformed washers, bracket cracks.
- Dimensional: measure bolt/stud diameter and bushing inside diameter; measure shock eye clearances and stroke condition. Record which parts to replace.
- Decision: replace only bushings/hardware if bracket/gussets fine; replace bracket or weld repair if cracked or holes elongated beyond repair.

4) Vehicle positioning and preload control (why it matters)
- Why: shock geometry and bushing compression depend on suspension ride height. Removing or installing mounts with wrong suspension position can bind the shock (preload) or leave it slack, accelerating failure.
- Procedure: lift vehicle and support frame safely. Support axle at ride height with jack stands or hydraulic support so leaf springs/air springs are carrying weight as if at rest. If uncertain, support so wheel unloaded slightly but consistent with OEM instructions.

5) Removing the old shock/mount (in order)
- Apply penetrating oil to nuts/studs, allow soak.
- Support the shock body or lower eye so it cannot fall when fasteners removed.
- Remove nuts/bolts at top and bottom. If bolts seized, heat the nut (not the bushing) or cut stud flush and drive out remaining shank. Avoid cutting into bracket unless replacement planned.
- Remove shock assembly. Inspect shock for bent rod, oil leakage — replace shock if damaged.

Theory note: removing hardware relieves the unwanted rotation and lateral load that accelerate bushing wear. Keeping the suspension at ride height prevents binding while hardware is out.

6) Removing old bushings and preparing bracket
- Press out old bushing or cut out rubber carefully with grinder; avoid enlarging bore.
- Clean bracket bore, remove corrosion, measure bore roundness. If bore is elongated or oblong beyond tolerance, replace bracket.
- If bracket cracked: cut out damaged section, prepare mating surfaces for new plate replacement. Do not attempt temporary fixes; fatigue cracks require full replacement or properly executed weld repair.

Theory note: worn bore allows relative motion and fretting; restoring correct bore diameter and face seating eliminates micro-movement and restores load distribution.

7) Bracket repair or replacement (if needed)
- Replacement: fit new bracket/assembly that matches OEM geometry.
- Welding repair (if performed): use correct filler (low hydrogen rod/wire appropriate to base metal), preheat if thick steel or per weld procedure, ensure full penetration, restore original hole location and orientation, grind smooth, stress-relieve if required by spec, and coat to prevent corrosion. Re-drill to correct diameter and use new hardened bush seats/washers where required.
- Re-check geometry and fit with new bushings dry-fit.

Theory note: proper bracket restore the distance and alignment so the damper operates in its designed motion envelope; welding must restore original stiffness to prevent altered dynamic loads.

8) Installing new bushings/shock/mount hardware (order & theory)
- Grease sleeve-type bushings only if OEM allows (many are bonded/grease-free). Use correct lubricant for the bushing material.
- Install inner sleeve/washer and outer sleeve as per orientation markings; ensure eyes are seated squarely in bracket faces.
- With suspension at ride height, fit bolt through bushing; tighten nut finger-tight first. Final torque only when both top and bottom are fitted and suspension at ride height to avoid preload.
- Torque nuts/bolts to OEM specification. If OEM spec unavailable, do not over-torque—torque enough to clamp bushings so they don’t rotate but not so much that bushings are fully compressed (this prevents bushing from performing as designed). Mark hardware for future inspection.

Theory note: bushings are designed to allow controlled compliance. Correct torque compresses washers against bushing faces preventing axial play while allowing the designed shear deflection during suspension movement. Over-torque eliminates shear working range and transmits loads into metal, causing noise/failure.

9) Replacing a welded-in stud (if present)
- If top stud is welded to shock perch and failed, remove old stud, chase threads in bracket if required, install new stud to proper depth and weld per procedure (if refitting to shock body, generally replace whole shock instead of welding).

Theory note: welded studs are high stress locations; replacing the shock unit is usually safer than on-vehicle stud welding which can distort or damage components.

10) Final checks, torque and test
- Torque all fasteners to spec and lock (lockwire/nyloc/washer per OEM).
- Verify shock travel is unobstructed through full droop/ride compression.
- Lower vehicle to ground, cycle suspension a few times, re-torque after initial settling (recommended re-check after first 100–200 km).
- Road test: check for noise, handling, and inspect for any movement or new cracks.
- Post-test re-inspect hardware and torque.

11) How each action directly fixes the fault (concise)
- Remove worn bushings: eliminates axial/lateral play that caused clunks and misdirected loads.
- New bushings and proper torque: restore controlled compliance—damping forces pass through shock instead of being absorbed by failed rubber, restoring handling and reducing wear.
- Replace cracked bracket/weld: remove stress riser and restore stiffness so loads are not concentrated into a failing area, preventing propagation of cracks.
- Replace corroded/elongated bolts: restore clamping preload and correct bolt shank diameter so shear/loading is as designed.
- Correct orientation and ride-height installation: prevents binding or over-extension of shock that otherwise shortens component life.

12) Verification measurements (what to check after repair)
- No perceptible play at mount when prying.
- Shock stroke unobstructed through full suspension travel.
- No oil leakage from shock, no unusual noises.
- Fastener torque within spec and no fretting at bracket.
- Re-check after 100–200 km.

Do this repair using OEM parts and follow Hino service manual torque and welding procedures where available.
rteeqp73

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