Safety first (read before touching anything)
- Work on a flat level surface, chock front wheels, engage park/engine off, disconnect battery.
- Use a rated jack and axle stands under recommended jacking points. Never rely on a jack alone.
- Wear safety glasses, gloves, steel-toe boots. Clean, well-lit area.
- Use torque-rated tools and calibrated measuring instruments. Follow Hino factory torque/specs where noted — this procedure shows method, not every exact Nm value (consult OEM manual for torque and shim chart).

Tools & consumables (minimum)
- Floor jack, heavy-duty jack stands, wheel chocks
- Impact wrench and breaker bar
- 1/2" and 3/4" torque wrench (or wrench rated for required Nm), crowfoot/adapter as needed
- Bearing puller / gear puller / 3-jaw puller
- Hydraulic press (or large shop press) and bearing/seal drivers
- Dial indicator with magnetic base (0.01 mm or 0.001" resolution)
- Depth micrometer or pinion depth gauge; vernier caliper/OD micrometer
- Feeler gauges, feeler blocks
- Pinion preload gauge (optional) or inch-pound torque wrench for preload measurement; small dial torque gauge for preload reading if possible
- Bearing separator and plates
- Heat source (induction heater or torch) for removing pressed-on components
- Dead blow hammer, soft mallet, pry bars
- Gear marking compound (Prussian blue / gear paint)
- Thread locker (Loctite), anti-seize compound
- Clean rags, solvent, parts cleaner, brake cleaner
- New differential oil (spec grade hypoid oil), oil pan, drain plug washer
- Replacement parts: pinion bearing(s) & races, carrier bearings & races, pinion seal, crush sleeve (if used) or pinion shims, ring gear bolts (replace if torque-to-yield or single-use), ring & pinion set (if worn/damaged), axle seals, side thrust washers, spider gears, carrier shim(s), gasket or gasket maker, studs/bolts as required
- Shop manual with torque specs, shim chart, bearing preload specs, and ring/pinion tooth specs

Overview of procedure (major steps)
1) Wheel/brake/driveshaft removal and differential drop or axle disassembly
2) Drain and remove differential carrier
3) Disassemble pinion & carrier, remove bearings/races
4) Clean and inspect all parts; replace bearings/seals and damaged gears
5) Set pinion depth and preload
6) Set ring gear backlash and bearing preload (carrier bearings)
7) Verify tooth contact pattern with gear marking compound; adjust until correct
8) Reassemble with correct torques, install seals, refill oil, test

Step-by-step procedure

1. Preparation and removal
- Park, chock, disconnect battery.
- Raise truck, support axle on heavy-duty stands per axle support points.
- Remove driveshaft at the flange (mark orientation for reassembly).
- Remove wheels if needed, brake drums/calipers and backing plates to access axle shafts.
- For semi-floating axles: remove axle shafts (C-clips or flange U-bolts depending on design). For full-floating truck axles: remove wheel hub, brake drum, and differential carrier per manual.
- Place drain pan; remove differential cover bolts and drain oil. Remove cover and gasket/residue.

2. Carrier removal
- With cover off, mark bearing caps and orientation for reassembly.
- Remove bearing cap bolts, lift out the carrier assembly (use pry bars carefully). If carrier is heavy, use hoist.
- Inspect ring gear and mounting bolts for looseness or damage.

3. Disassembly of pinion and bearings
- Mark orientation of driveshaft flange/companion flange to pinion for reassembly.
- Remove pinion nut/retaining nut (impact or breaker). If a crush sleeve is present, note it must be replaced.
- Remove driveshaft companion flange with puller; use slide hammer or puller to avoid damage.
- Remove pinion gear, bearings, races. Use puller or press. Remove pinion seal (careful not to score housing).

4. Cleaning and inspection
- Clean housing, carrier, gears in solvent. Blow out oil galleries.
- Inspect ring and pinion for pitting, scoring, chipped teeth, or excessive wear. If any damage beyond minor scoring, replace ring & pinion set.
- Inspect bearings and races; replace both pinion and carrier bearings and races—do not reuse bearings.
- Inspect carrier for cracks, bearing bores for wear. Replace carrier if bores worn.

5. Preparing installation & measuring baseline
- If installing new ring & pinion, press new bearings onto pinion and carrier (heat bearings or freeze bearing when needed; use press and bearing drivers).
- For pinion depth (shim method or engineered spec): measure original pinion depth (distance from pinion face to reference on housing) before removing if possible, or use OEM shim chart. Use depth micrometer to measure flange face to ring gear bore centerline or follow manual’s measurement method.
- If crush sleeve design: prepare new crush sleeve and new pinion nut.

6. Setting pinion preload (two common methods)
- Shim type:
- Install pinion with appropriate shim thickness, bearings, and pinion nut snug (not final). Install carrier temporarily and measure pinion bearing preload using a torque wrench on pinion nut (measure starting torque then turn pinion and note breakaway torque). Adjust shim thickness to achieve specified preload (OEM spec in Nm or in-lb). Final torque for nut per manual.
- Crush sleeve type:
- Install new crush sleeve, bearings, pinion. Tighten pinion nut gradually until specified preload is achieved (usually measured as rotational torque on pinion; specified inch-lb or Nm). Crush sleeves are one-time-use — replace always. Do not over-crush or under-crush; over-crushing destroys bearings.
- Tool use: torque wrench for pinion nut (or inch-pound torque gauge for preload), depth micrometer for shim measurements, press and drivers for bearings.

7. Install ring gear on carrier
- If ring gear was removed (for replacement), clean mating surfaces. Heat ring gear evenly (oil bath or induction heater) to expand, fit to carrier, seat bolts finger tight, follow star pattern tightening to spec. Use thread locker if specified. Torque to OEM sequence and value.
- Measure runout of ring gear with a dial indicator mounted to housing; replace if runout exceeds spec.

8. Setting backlash
- Install carrier with new bearings into housing using new carrier shims as required; tighten bearing caps to spec.
- Use dial indicator with magnetic base mounting to the housing to measure ring gear backlash: indicator tip on tooth root, rotate pinion back and forth while holding carrier to measure total movement. Backlash specified in manual (typically 0.10–0.20 mm for many axles, but consult Hino chart).
- Adjust backlash by changing carrier side shims (move carrier closer to or further from pinion). Thicker shim on drive side reduces backlash; thinner increases. Repeat measurement after each change until backlash is within spec.
- Tool use: dial indicator, set-up: indicator base against housing, tip on tooth, ensure indicator zeroed and reading stable.

9. Check tooth contact pattern and final adjustments
- Apply thin layer of gear marking compound to ring gear teeth across several teeth.
- Rotate ring gear two full revolutions in both directions under light load (rotate driveshaft) to get contact patch.
- Inspect contact pattern: ideal contact sits slightly toward the toe and center of the tooth depending on pinion depth. If pattern is too close to face or root, adjust pinion depth or backlash accordingly (pinion depth shifts pattern along tooth; backlash shifts pattern circumferentially).
- Repeat shimting or pinion depth change until pattern matches OEM ideal pattern.
- Common tool use: gear marking compound, dial indicator to ensure backlash maintained after adjustments.

10. Final torques and bearing caps
- Once pattern is correct and preload/backlash within spec, apply Loctite where specified and torque ring gear bolts to spec in proper sequence.
- Torque bearing caps to spec (matching original orientation and cap marks).
- Re-check backlash after final torque; small changes may occur — readjust if necessary.

11. Reinstall pinion seal, companion flange, differential cover
- Install new pinion seal using a seal driver. Install driveshaft flange and torque nut to spec.
- Install new differential cover gasket or RTV, torque bolts in cross pattern to spec.
- Reinstall axle shafts, hubs, brakes, wheels as required.

12. Fill, test, and road-check
- Refill differential with specified hypoid oil to correct level.
- Reconnect driveshaft, torque flange bolts to spec.
- Lower vehicle, torque wheel lug nuts to spec.
- Road test with progressive load and listen for whine/noise. Re-check for leaks. Re-inspect pattern if abnormal noise persists.

Common pitfalls and how to avoid them
- Reusing crush sleeve or shims without verification — always replace crush sleeve; verify shims for re-use only if within spec and undamaged.
- Incorrect pinion preload (too loose -> noise, too tight -> premature bearing failure). Use a calibrated preload method; do not rely on torque-only for bearings when crush sleeve used.
- Improper pinion depth — this ruins tooth pattern. Use depth micrometer and shim charts or trial fitting with pattern compound.
- Not replacing bearings & races — re-use of old races with new bearings destroys them. Replace both.
- Overheating ring gear when heating — heat evenly to avoid warping. Don’t use open flame directly on gear teeth.
- Not cleaning surfaces thoroughly — dirt/metal filings cause leaks and wear.
- Over-torquing bolts (especially ring gear bolts or pinion nut) — use correct torque in sequence; replace torque-to-yield fasteners.
- Not checking runout — excessive runout leads to noise even if backlash/pattern seem OK.
- Not torquing bearing caps evenly — this can distort carrier and change backlash.

Replacement parts typically required
- Pinion bearings & races (inner & outer), carrier bearings & races
- Pinion seal (always)
- Crush sleeve or pinion shims (as required)
- Ring & pinion set (if wear/damage)
- Ring gear bolts (replace if single-use or damaged)
- Axle seals, gaskets, studs/bolts as needed
- Differential oil
- Side thrust washers, spider gears if worn

Quick notes on specific tool usage
- Dial indicator: mount base to rigid housing surface (frame or housing), tip on tooth root or tooth face depending on measurement. Zero and slowly rock pinion back and forth to measure backlash.
- Depth micrometer/pinion depth gauge: measure to the reference surface (follow manual method — often measure from pinion nose to ring gear centerline edge or use test patterns).
- Bearing separator & press: use separator under bearing race, press on bearing inner diameter or use a driver to press on the correct surface. Do not press on rolling elements.
- Bearing puller: engage lip of bearing or race, pull steadily; use heat on housing if stuck.
- Heat ring gear: uniform heat in an oil bath or induction heater (~120–150°C) to expand before pressing onto carrier; avoid direct torch to preserve hardness.

Final verification
- After reassembly and fill, idle-run and inspect for leaks. Short drive then re-check pinion nut and ring gear bolt torque where specified by OEM.
- Road test under load; noisy or vibrating differential indicates pattern/backlash error — do not ignore.

Follow the Hino workshop manual for model-specific torque values, shim lists, and factory patterns. The above is the full procedure and critical checks you must perform during differential gear repair on Hino FD/FE/FF/SG/FA/FB series.
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