Tools & consumables (minimum)
- Safety gear: gloves, eye protection, steel-toe boots.
- Workshop manual for Hino Super F Series GH1H (exact torque, shim, and spec values).
- Engine hoist or crane; heavy-duty transmission jack with adapter.
- Floor jack + axle stands or full vehicle lift.
- Wheel chocks, blocks, and mirror for under-vehicle checks.
- Basic hand tools: metric socket/ratchet set, deep sockets, combination wrenches, breaker bar, extensions.
- Torque wrench (suitable range for truck fasteners).
- Impact wrench (for removal only).
- Screwdrivers, pry bars, dead blow hammer.
- Bearing puller / gear puller.
- Hydraulic press (30–50 ton recommended for truck bearings/gears).
- Snap-ring pliers (internal & external).
- Seal driver / drift set.
- Magnetic tray / parts bins and marker for tagging parts.
- Dial indicator with magnetic base (for endplay/runout).
- Feeler gauges, straight edge, Vernier calipers, micrometer.
- Punch & brass drift set.
- Drift and rubber mallet.
- Thread locker, anti-seize, RTV sealant (if specified).
- New transmission fluid (manufacturer grade), drain pan, disposable rags.
- Clean workbench, parts washer or solvent.
- Replacement gaskets, seals, bearings, synchro rings, snap rings, shift forks (see parts list below).
- Clean assembly lube or gear oil for assembly.
- Torque angle gauge (if required by spec).

Safety & preparation
1. Work on a flat, level surface. Chock wheels and place vehicle on a lift or heavy-duty stands. Never rely solely on a jack.
2. Disconnect battery negative terminal.
3. Drain transmission fluid into approved container (avoid spills).
4. Support engine/transmission weight: use engine support bar or hoist in addition to the transmission jack when separating from engine.
5. Wear PPE and keep bystanders clear of the load path when lifting or lowering the transmission.

Typical replacement parts to have on hand
- Main shaft & countershaft bearings (all).
- Input shaft bearing & pilot bearing (if used).
- Output shaft seal, input seal, tail housing seal.
- Synchronizer rings (all worn synchromesh units).
- Shift forks (replace if bent or worn at contact surfaces).
- Shift rails, bushings, springs, detent balls/springs.
- Gaskets and O-rings for cover/housing.
- Snap rings, thrust washers, shims (as required).
- Fasteners (replace any damaged/ stretched bolts).
- Transmission fluid (manufacturer spec).

Step-by-step procedure

A. Removal (from vehicle)
1. Prepare: drain fluid, disconnect battery. Tag and disconnect speedometer cable/sensor, PTO lines, electrical connectors to gearbox and neutral safety switches.
2. Remove driveline: mark and detach prop shaft U-joint/ drive shaft from transmission output flange.
3. Remove external linkages: detach gearshift link, shift rod, clutch slave/master lines if necessary. Label everything.
4. Support engine and transmission: position engine hoist or support bar to take engine load when trans is dropped.
5. Remove starter and bell housing bolts: unbolt clutch housing bolts. Remove clutch inspection cover(s).
6. Unbolt transmission mount(s) and crossmember(s). Support gearbox on transmission jack.
7. Slide transmission rearwards until input shaft clears clutch pressure plate/flywheel. Carefully lower with transmission jack. Prevent tilting that can damage tail housing or input shaft.

B. Bench prep & pre-disassembly checks
1. Clean exterior and mark orientation of covers, linkage, and wiring.
2. Photograph assembly for reassembly reference.
3. Remove top cover and drain residual fluid again. Keep fasteners sorted and labeled.

C. Disassembly (organized, methodical)
1. Remove shift rails and detent mechanisms; note spring/ball positions.
2. Remove selector housing/covers and snap rings with circlip pliers.
3. Remove input shaft assembly: take out bearing retainer, snap rings, and slide input shaft out.
4. Remove main shaft & countershaft assemblies as subassemblies. Use press or bearing puller for stuck bearings.
5. Remove bearings, synchro hubs, synchronizer rings, shift sleeves. Use snap-ring pliers to remove internal clips.
6. Remove output shaft and tail housing; remove tail housing seals carefully.
7. Where gears are interference-fit on shafts, use hydraulic press and appropriate adapters to press gears off. Use proper support to avoid shaft bending.
8. Keep all parts in order and on labeled trays in the sequence they came off.

Tool use details
- Transmission jack + crane: cradle gearbox, lift and align with engine input. Lower slowly while guiding input spline into clutch disc; never force.
- Hydraulic press: support shaft ends on press blocks; use adapters to press bearings off evenly. Protect gear teeth with soft jaws or copper/brass drifts where appropriate.
- Bearing puller: center jaws square on bearing race; apply steady force; avoid pulling on the cup if it’s pressed into the housing (use appropriate internal/external puller).
- Dial indicator: measure input/mainshaft endplay and gear runout. Mount magnetic base to housing; move indicator contact onto specified face; rotate shaft to record runout and backlash.
- Torque wrench: tighten fasteners to factory spec in the correct sequence, use calibrated tool; if angle torque specified use torque-angle gauge.
- Snap-ring pliers: expand/compress rings carefully to avoid deformation and ensure they seat in groove.

Inspection & measurements
1. Bearings: roll and listen for roughness, torque frees up. Replace all worn or noisy bearings.
2. Gears: inspect teeth for pitting, chipped teeth, scoring, or excessive wear. Replace damaged gears or entire shaft if teeth are compromised.
3. Synchros: check friction surface wear, chamfer condition; replace if glazed, uneven or below thickness.
4. Shafts: inspect spline wear, shoulder wear and straightness. Check bearing journals with micrometer; compare to service limits.
5. Bushings & forks: check fork tips and slider areas for wear or elongation; replace tails or forks if deformed.
6. Seals & gaskets: always replace seals. Replace gaskets if removed.

Critical adjustments & reassembly
1. Clean all parts thoroughly before reassembly; avoid contamination.
2. Install new bearings and seals using drivers and press. Heat/ice technique is acceptable for small interferences but use press when possible.
3. Replace all snap rings and ensure they seat fully in grooves.
4. Reinstall shafts, synchronizers and gears in correct orientation and order. Use factory shims or replace with new to set bearing preload and endplay.
5. Check bearing preload and shaft endplay with dial indicator. Adjust with shims as specified in the workshop manual until within spec.
6. Check gear backlash between mating gears; adjust shims if required.
7. Reinstall shift forks and rails; verify free, smooth operation of all shift positions. Lubricate sliding surfaces with assembly grease.
8. Torque all housing and cap bolts to the exact values and sequence in the Hino manual.

Sealing & final assembly
1. Replace gasket/sealant per manual (type and cure time). Use correct RTV where noted; do not over-apply.
2. Refit tail housing, covers, and external components making sure shift linkage returns to neutral alignment.
3. Pre-fill transmission with a small amount of fluid to lubricate bearings upon first rotation.
4. Rotate input/output shafts by hand to check for binding and to seat parts.

Reinstallation in vehicle
1. Align clutch disc splines and pilot bearing; use alignment tool for clutch if clutch removed.
2. Raise transmission on jack, align input shaft with transmission bell housing and bell to engine. Make sure dowel pins align; take care not to damage pilot bearing.
3. Bolt bell housing to engine finger-tight first then torque in sequence to spec.
4. Reinstall crossmember, mounts, starter, driveshaft and linkage. Reconnect speedometer, sensors.
5. Refill transmission with correct Hino-specified fluid to recommended level.
6. Reconnect battery.

Testing & break-in
1. Start engine; check for leaks, abnormal noises, oil pressure if fitted.
2. With parking brake on, cycle through gears with clutch depressed to ensure proper selection and that synchronizers engage cleanly.
3. Road test under light load first. Listen for noise, check shifting under load. Re-check fluid level when warm.
4. After initial run-in (per manual recommendations), re-torque accessible external fasteners and re-check for leaks.

Common pitfalls & how to avoid them
- Not using factory manual specs: always use Hino torque, shim, and preload specs; guessing leads to premature failure.
- Re-using worn bearings, seals, synchros: these should typically be replaced when transited; reused items are frequent causes of re-failure.
- Improper bearing preload or endplay: incorrect preload causes noise, overheating, or premature wear — measure with dial indicator and set shims precisely.
- Contamination during assembly: dirt or metal chips ruin bearings/gear faces. Keep parts clean, use lint-free rags and solvent.
- Forcing shafts together: misalignment can damage splines or pilot bearings — use alignment tools and guide bolts.
- Re-using snap rings or deformed fasteners: replace damaged rings/bolts; they’re inexpensive compared to a failure.
- Wrong fluid: use manufacturer-specified gear oil; incorrect viscosity or additives harm synchronizers.
- Skipping shift linkage adjustment: misadjusted linkage causes false “internal” complaints and hard shifting.
- Incomplete verification: failing to re-check torque after first run or to test-drive under varying loads.

When to consider replacement vs repair
- Replace shafts or gears if teeth are chipped, splines badly worn, or journals out of tolerance.
- Replace entire set of bearings and all seals as a minimum when rebuilding.
- Replace synchronizers as a set if one is worn—mixed wear leads to uneven shifting.

Final notes
- Keep a clean workspace and document every step (photos and labeled parts).
- If any dimension or torque is unknown, stop and consult the Hino GH1H workshop manual — do not guess.
- If you don’t have press/pull capacity or experience setting bearing preload and backlash, have a specialist perform those stages.

This procedure is a generic, complete rebuild workflow for a Hino Super F Series GH1H manual transmission. Follow the Hino workshop manual for all numerical specs, sequences, and Hino-specific components.
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DRIVING FORCE Safety Video - Operation of 24' Hino Trucks

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