Ordered workshop-style differential service with theory and “how the repair fixes the fault.” No filler.

Prerequisite: have the Hino OEM service manual/specs at hand (torques, shim thicknesses, backlash/pattern tolerances, correct lubricant and capacity). Tools required: jack/stands or lift, torque wrench, bearing puller/press, arbor press, dial indicator with magnetic base, pinion depth tool or micrometer + fixture, gear marking compound, micrometer/calipers, bearing race driver, soft hammer, seal driver, breaker bar, carrier spreader or shim tools, shop press, clean rags, solvent, new bearings/seals/crush sleeve or pinion shims, new ring & pinion if worn.

1) Diagnose and document fault
- Action: Road test noting noise type (low rumble/growl = bearings; whining = pinion depth/backlash; clunking = play or broken teeth; vibration = imbalance/axles). Check for leaks, magnetic drain plug metal, metal in oil, play at wheels.
- Theory: Noise source maps to component condition: bearings produce rough rumble and looseness; gear whine arises from incorrect tooth contact from wrong pinion depth/backlash; metal/contamination accelerates wear.
- How repair fixes it: Replacing worn bearings/seals and reestablishing correct gear geometry removes the mechanical source of noise, play and wear and prevents progressive damage.

2) Prepare vehicle and safety
- Action: Securely lift and support; remove wheels; release parking brake; tag driveline orientation; mark driveshaft yokes and carrier orientation.
- Theory: Preserving orientation avoids introducing new imbalance or phasing errors.
- Fix effect: Prevents new driveline vibration and makes reassembly identical to known baseline.

3) Drain differential oil and inspect fluid
- Action: Drain into a pan; inspect for metal flakes, scoring, or contamination.
- Theory: Metal in oil indicates bearing or gear wear/breakage; contaminated oil accelerates failure.
- Fix effect: Removing contaminated oil and replacing with new prevents continued abrasive wear; metal findings inform parts to replace.

4) Remove external components and gain access
- Action: Remove axles/halfshafts (or remove wheel hubs depending on axle type), brake assemblies, driveshaft, and differential cover or remove axle housing cover as required for your Hino model. Keep fasteners organized.
- Theory: Access required to remove carrier and pinion; removing axle shafts allows removal of carrier in most designs.
- Fix effect: Allows direct inspection and work on internal components.

5) Remove carrier (ring gear/case) and pinion
- Action: If shim-type, record shim positions. Loosen carrier bolts, remove carrier. Remove pinion nut and withdraw pinion (press as needed). Remove bearings and races for bench inspection.
- Theory: Disassembly reveals wear and allows measurement of pinion depth, ring gear runout, bearing condition.
- Fix effect: Enables replacement of worn elements and re-establishment of correct bearing preloads and gear tooth engagement.

6) Inspect parts and decide repair scope
- Action: Inspect ring & pinion teeth for pitting, scoring, broken teeth; inspect bearings for brinelling; check bearing races; check carrier bores for wear; check housing alignment/split face.
- Theory: Surface damage shows the root cause — e.g., abrasive contamination, excessive preload, poor tooth contact, or shock loading.
- Fix effect: Replace damaged gears/bearings to eliminate noise sources and prevent catastrophic failure.

7) Measure and record baseline geometry
- Action: Measure pinion depth (pinion head relative to carrier mounting face), backlash with dial indicator, ring gear runout, and bearing bores. Record dimensions.
- Theory: The correct tooth contact pattern depends on precise pinion depth and backlash. Changing bearings/shims changes geometry.
- Fix effect: Measurements tell you how far off geometry is and what shims/crush sleeve settings are needed to return to spec.

8) Replace bearings, races, seals, crush sleeve (one-time-use) as required
- Action: Press off old bearings, install new races and bearings with proper drivers and heat if permitted. Replace pinion crush sleeve or use new shim as specified. Replace oil seals and axle seals.
- Theory: Bearings wear and increase clearance; races can gall. Crush sleeve sets pinion preload; seals prevent contamination.
- Fix effect: New bearings restore correct clearances and smooth rolling; new crush sleeve/pinion nut allows setting correct preload; seals prevent oil loss and ingress of dirt.

9) Set pinion depth and pinion preload
- Action: Install pinion with new crush sleeve or shims and tighten to set preload per OEM procedure (or to specified torque/crush). Use pinion depth tool or measure with micrometer and fixture to set to specified depth.
- Theory: Pinion depth determines where the pinion tooth contacts the ring tooth face-to-toe; incorrect depth causes whine and accelerated wear. Pinion preload sets bearing internal pre-tension to eliminate play while not overstressing bearings.
- Fix effect: Correct depth produces ideal tooth contact pattern (centered, correct position). Correct preload prevents axial play/noise and avoids overheating bearings.

10) Install carrier with new shims and set backlash
- Action: Place carrier with ring gear and install initial shim pack. Measure backlash with dial indicator on ring gear teeth while rotating. Adjust carrier shims to obtain OEM backlash spec. Tighten carrier bolts to torque.
- Theory: Backlash (radial clearance between ring and pinion) controls clearance at the tooth flank and affects contact across the tooth face. Too little = binding & noise; too much = impact, tooth wear and fatigue.
- Fix effect: Correct backlash and pinned depth together position the tooth contact pattern so load is distributed properly; this reduces noise and prevents localized wear and tooth failure.

11) Check and refine tooth contact pattern
- Action: Apply gear marking compound to several teeth, rotate pinion several revolutions under loaded torque (use pry bar on flange) and observe pattern. Interpret: contact toward toe/heel indicates pinion depth error; contact toward face/root indicates backlash issue. Adjust shimring/pinion depth and backlash iteratively until pattern falls in OEM-specified zone (normally centered on tooth face and length with a slight bias depending on gear).
- Theory: The contact pattern visually shows the actual mesh of teeth. Correct pattern ensures the contact is centered for maximum load capacity and even lubrication.
- Fix effect: Ensures the gears share load properly across the tooth surface, eliminating whine and preventing scalloping, pitting, or early failure.

12) Set carrier bearing preload (if applicable)
- Action: Where applicable, set carrier bearing preload by tightening side adjusters or by torque-on-turn method as per manual. Measure rotational torque and compare to spec.
- Theory: Carrier preload prevents lateral play of the carrier that would change backlash under load.
- Fix effect: Proper preload stabilizes gear geometry under load and prevents backlash change, noise, and impact loading.

13) Final assembly: seals, cover, fill
- Action: Install new pinion and axle seals, cover/gasket or RTV per OEM, reinstall axles, brakes, driveshafts. Refill differential with the specified gear oil and additive if required to the correct level.
- Theory: Clean seals and proper lubricant maintain the operating environment for bearings and gears. Gear oils provide film strength for tooth surfaces and bearing lubrication.
- Fix effect: Prevents contamination and maintains lubrication film to stop metal-to-metal contact and wear.

14) Break-in and verification
- Action: Torque-check critical fasteners after initial run (per manual). Road test at variable speeds and loads. Re-check backlash and tooth pattern after short service interval (e.g., 50–200 km or as OEM suggests). Check for leaks and unusual noises.
- Theory: New gears/bearings seat together under load and initial torque may settle; re-checking ensures adjustments remain within tolerance.
- Fix effect: Confirms repair was successful and prevents rework.

Interpretation of common fault fixes (quick mapping)
- Whine at speed (steady, pitch changes with RPM): Usually pinion depth/backlash/contact pattern. Fix: reset pinion depth and backlash so teeth mesh correctly; replaces worn gear if damaged.
- Growl/rumble: Worn carrier or pinion bearings. Fix: replace bearings and races, set preload.
- Clunk on acceleration/deceleration: Excessive backlash or worn splines/axle engagement. Fix: correct backlash and replace worn splines or U-joints/driveline parts.
- Oil leak: Worn seals or loose cover. Fix: replace seals, tighten and re-seal cover, ensure correct fill level.
- Metal in oil: Likely pitting or bearing destruction. Fix: inspect and replace damaged gears/bearings, thoroughly clean housing and refill.

Critical theory points to follow
- Pinion depth and backlash are interdependent: changing one affects the other; set pinion depth first (pinion depth sets where the gear faces meet), then adjust backlash with carrier shims, then re-check pattern.
- Bearing preload is crucial: under-preload = play & noise; over-preload = heat & premature bearing failure.
- Tooth contact pattern is the final arbiter: even if backlash and depth are to spec, the visual pattern tells you whether the mesh is correct.
- Cleanliness and correct lubricant prevent surface fatigue and abrasive wear; metal debris must be removed completely.
- Use OEM specs. Many components (crush sleeves, certain shims) are single-use — do not reuse.

Finish: After following the above procedure and verifying pattern/torques and lubricant, fault conditions are removed by (1) eliminating worn components that caused noise and looseness, (2) restoring correct gear geometry so contact forces are distributed across the tooth surface, and (3) sealing and lubricating the assembly to prevent contamination and further wear.

End.
rteeqp73

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