Tools & consumables (minimum)
- PPE: safety glasses, gloves, steel-toe boots, hearing protection.
- Wheel chocks, heavy-duty jack and rated axle stands (support frame, not tires).
- Battery disconnect tools.
- Hydraulic pressure-relief tools: operate controls to dump pressure, and follow OEM depressurization procedure.
- Metric/ SAE hand tools: sockets, ratchets, breaker bar, extensions, torque wrench.
- Impact wrench (air or electric) and lug tools.
- Large snap‑ring pliers, drift punches, soft‑face hammer, dead blow.
- Bearing puller / hub puller / gear puller.
- Hydraulic press (bench press or shop press) with suitable adapters.
- Heat source (induction heater or propane torch) for expanding hubs (careful).
- Dial indicator with magnetic base (for backlash), feeler gauges, micrometer.
- Plastigage or torque-turn/torque-angle tools (for preload where needed).
- Cleaning supplies: solvent, lint‑free rags, brushes.
- Threadlocker (medium/high strength per OEM), anti-seize.
- Grease and gear oil per Toyota specification.
- Replacement parts kit: planetary gear set (sun, planets, ring if necessary), planet carrier (or carrier rebuild kit), bearings (tapered/roller as used), seals/O‑rings, snap rings, shims/spacers, bolts (replace if torque-to-yield), hub gasket if present. Filters & hydraulic oil if contamination suspected.

Safety & preparatory precautions
1. Park on level ground, lower arms/bucket to rest on ground. Block machine and wheels.
2. Shut engine off, remove key, disconnect negative battery terminal.
3. Follow OEM hydraulic depressurization: run hydraulic controls to relieve residual pressure, then cap and plug lines immediately to prevent contamination.
4. Support machine on rated stands under frame/axle points — never rely on the loader arms or tires.
5. Wear PPE and keep hands/cloths clear of pinch points. Keep a clean work area to avoid contamination of components.

Step-by-step planetary gearbox repair (general workflow for SGK6/SDK6/SDK8 final drive planetary)
Note: follow the Toyota workshop manual for model-specific fastener torques, shim dimensions, and hydraulic procedures. The steps below are the complete logical sequence used in the shop.

1. Diagnosis & preparation
- Verify symptoms (noisy final drive, crawling, slipping, oil leak, overheating).
- Inspect for external leaks, damaged hoses, abnormal play at wheel hub.
- Obtain the OEM repair kit/parts list for the affected final drive — replace bearings and seals as a minimum when opening the unit.

2. Isolate and remove wheel/hub assembly
- Chock and support machine. Remove wheel or track hub cover to access hub bolts.
- Remove wheel or hub bolts; if hub is seized, use heat + puller. Keep track of shims/spacers and orientation of parts.
- Drain gearbox oil if unit has a drain. Collect for inspection (metal particles indicate gear/bearing failure).

3. Separate hydraulic motor / final drive housing (if applicable)
- Label and disconnect hydraulic lines; plug immediately to prevent contamination.
- Unbolt the hydraulic motor from the final drive housing (or remove motor-housing flange bolts).
- Carefully slide motor away checking for splines; support motor to avoid stressing lines.

4. Disassemble planetary carrier
- Remove external retaining rings, bolts, and carrier cover/plate.
- Note and mark positions of shims, spacers, and planet positions if reusing carrier.
- Remove planets and planet pins/cages—count and inspect each planet and pin. Use press or drift and hammer as needed.
- Remove sun gear and any thrust washers.
- Remove ring gear if removable (may require press or heating the hub).

5. Remove bearings & inspect components
- Use puller/press to remove bearings from sun, carrier and ring as needed.
- Clean all components with solvent and inspect:
- Gears: check tooth surfaces for pitting, spalling, scalloping, match marks, scoring or heat discoloration.
- Bearings: check rollers/cones for brinelling, pitting, cage damage.
- Carrier: check pin bores and mating faces for wear.
- Seals and O‑rings: if hardened or cut, replace.
- Decision: replace any component with visible wear/damage. Replace bearings and seals always when unit opened. Replace ring/sun/planet gears if tooth damage or excessive wear.

6. Prepare new parts & housings
- Clean housing bores and mating surfaces; remove old gasket/RTV.
- Press new bearings in using proper sleeves to avoid applying press force through inner race unless that is intended — press on correct race per bearing design.
- Install new snap rings in grooves before final assembly where applicable.

7. Rebuild carrier & set gear mesh / backlash
- Reinstall planets onto carrier pins; use new pins/retention and apply assembly lube.
- Install sun gear and carrier into housing.
- Refit ring gear and any carrier cover.
- Set backlash between ring gear and planet/sun gear using shims as specified by OEM. Use dial indicator against ring gear while rotating assembly to measure backlash. Typical acceptable backlash is small (consult OEM); carefully add/remove shims to get correct clearance.
- If gearset uses preload on bearings, set bearing preload per manual using torque-to-turn or torque measurements or using specified shims. Use plastigage or torque-turn method only if manual prescribes. Too much preload = overheating and bearing premature failure; too little = play/noise.

8. Reinstall hydraulic motor / hub
- Align splines and carefully slide motor onto shaft; do not force — lube splines with specified grease if required.
- Torque motor mounting bolts to OEM spec; use threadlocker where specified.
- Reinstall hub/wheel assembly, torque hub bolts to spec.

9. Seals and final checks before filling
- Replace drain/fill plugs with new washers if specified.
- Clean mating faces, apply sealant per manual where necessary.
- Refill gearbox with correct grade and quantity of gear oil. Replace hydraulic filters if contamination suspected and top up hydraulic reservoir.

10. Commissioning & testing
- With machine still supported, reconnect battery.
- With an assistant in cab or remote controls per OEM safety, cycle hydraulic controls to bleed air from motor/drive (follow bleed sequence).
- Slowly run engine/drive at low speed, check for leaks, abnormal noises, and correct operation.
- Check oil level again after warm-up and add if necessary.
- Road/field test under light load and re-torque accessible fasteners after initial hours per OEM recommendation.

How each tool is used (essential points)
- Hydraulic press: press bearings on/off using correct adapter to avoid damaging races. Press on the part of the bearing that is supported by the race you intend to move.
- Bearing puller / hub puller: attach evenly, pull straight without tilting. Use heat on hub if seized; avoid hammering bearing bores.
- Dial indicator: mount on stationary housing and contact ring gear face. Rotate slowly and record total indicator reading (backlash). Adjust shims and re-measure.
- Snap-ring pliers: remove/install snap rings fully into their grooves; verify rings are fully seated.
- Heat (induction heater/torch): heat hub evenly to expand for bearing/ring removal or installation — don’t overheat (avoid discoloration, tempering). Use heat to expand the outer part, then install inner component quickly before cooling.
- Plastigage (if used for preload): place strip on bearing journal, assemble nut to spec, disassemble and measure flattening to compute clearance per plastigage chart.
- Torque wrench: torque bolts in correct sequence & to OEM values; use calibrated wrench.

Common pitfalls & how to avoid them
- Not depressurizing hydraulics — risk of sudden movement and injury. Always relieve lines and plug them.
- Contamination: dirt or moisture in gears/bearings kills them quickly. Work in clean area, cap lines, use lint‑free rags, and clean parts before assembly.
- Reusing bearings or seals — leads to high failure rate. Replace bearings/seals whenever unit opened.
- Incorrect bearing press technique — pressing on the wrong race damages bearing internal components.
- Incorrect backlash/preload — causes noise, premature wear, or overheating. Always set to OEM spec and verify with dial indicator / torque-turn procedure.
- Improper torque / reused hardware: some bolts are torque-to-yield and must be replaced. Always follow OEM callout.
- Overheating during removal/installation: overheating gears/shafts can alter temper and cause failure. Use controlled heating.
- Ignoring hydraulic motor wear: damage to motor spline or shaft can cause rapid failure; inspect carefully and replace motor if worn.
- Not replacing filter/flushing system after internal failure — debris will re-fail new parts. Clean reservoir and lines or replace hydraulic fluid/filter after repair.

Replacement parts typically required
- Planetary repair kit: planet gears, sun gear, ring gear (if worn), planet pins, carrier components (or whole carrier).
- Bearings (all bearings in assembly), seals & O‑rings, snap rings.
- Shims/spacers (backlash and preload adjustment).
- Housing gasket or RTV sealant, oil drain/fill washers.
- Hydraulic oil and filters if contamination occurred.

Final notes
- Always cross-check with Toyota SGK6/SDK6/SDK8 workshop manual for exact procedures, part numbers, torque values and shim tables.
- If gear teeth show pitting/spalling or bearings show significant damage, replace the gear set or carrier rather than attempting a partial repair — this avoids repeat failure.
- After repair run-in, re-check torque and oil level after the first few hours of operation.

End of procedure.
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