Safety first
- Work on level ground with wheels chocked. Wear safety glasses, gloves and steel-toe boots.
- Disconnect battery negative. Support engine/transmission with an appropriate transmission jack and engine support before removing mounts.
- Use proper lifting gear rated for the weight of the Hino 500 transmission. Never crawl under a vehicle supported solely by jacks.
- Keep a clean, well-lit workspace and use drip pans for gearbox oil.

Required tools (typical)
- Full metric socket/ratchet set, extensions, breaker bar.
- Torque wrench (suitable range to factory specs).
- Transmission jack or floor jack with adapter and engine support/bracing.
- Snap-ring/circlip pliers (internal & external).
- Bearing puller / gear puller.
- Press or arbor press (for bearings/bushings).
- Drift punches, soft-faced mallet.
- Feeler gauges and straight edge.
- Dial indicator with magnetic base (for end float/backlash checks).
- Puller for input shaft / pilot bearing (if needed).
- Seal drivers and oil seal installer.
- Clean rags, parts trays, solvent, assembly grease.
- Replacement gaskets, seals, new shift fork(s), new bushings/bearings/sync rings as required.
- Workshop manual (Hino 500 Series) for torque figures and specific disassembly order.

Common replacement parts to have on hand
- Shift forks (specific to Hino 500 model & gearbox code).
- Selector shafts/rods bushings or sleeves.
- Synchronizer rings and hubs (if worn).
- Bearings and thrust washers that show wear.
- Oil seals, O‑rings, gaskets, and transmission oil.
- Circlips and fasteners (do not reuse damaged rings).

Step‑by‑step procedure (general workshop-level workflow)
1) Prepare and lift
- Park truck on level ground, chock wheels, disconnect battery negative.
- Remove cab or tilt as required for access (follow Hino procedure).
- Support engine/trans with engine support tool if needed. Raise and safely support vehicle on stands.

2) Drain and disconnect
- Drain transmission oil into a clean container. Keep for contamination check or dispose.
- Remove drive shafts/propshafts, PTO if fitted, speedometer cables/sensors, electrical connectors, and any linkage to the shifter.
- Label linkage and wiring for reassembly (use tape/tags).

3) Remove transmission from vehicle
- Unbolt bellhousing from engine (separate clutch housing if manual/dual mass). Remove clutch/pressure plate/flywheel if gear removal requires it.
- Use a transmission jack to lower the gearbox. Carefully withdraw transmission from the engine and lower to bench.

4) External disassembly to access shift mechanism
- Clean external surfaces to avoid dirt ingress. Remove top covers, shift housing/selector housing bolts, and any mounting brackets. Keep parts in the order removed and mark orientation.
- Remove the shift lever/seal and shift linkage from the selector drum/rails.

5) Internal disassembly (selector shafts & forks)
- Remove selector rail retaining bolts/circlips. Carefully slide selector rails out. As you withdraw rails, shift forks will lift free — note orientation and which fork corresponds to which rail/gear.
- If forks are retained by pins, remove pins retaining fork to rail; use circlip pliers or drift as required.
- Inspect selector rails and fork contact surfaces for wear, scoring or bending.

6) Remove and inspect shift forks and associated components
- Withdraw shift forks. Mark forks and mating synchronizer hubs so they go back to same positions if reusing.
- Inspect fork contact pads (wear, grooving), fork ears, bushings/sleeves and synchronizer teeth. Measure wear against allowable limits in the Hino manual.
- Check selector rod bores and bushings for ovality. Replace bushings if loose/worn.

7) Replace parts and prepare for reassembly
- Replace shift forks with OEM specified parts if wear/damage present. Replace any worn synchronizer rings, hub sleeves, selector rail bushings and bearings.
- Press in new bushings or bearings with an arbor press, ensuring square seating. Use seal driver for seals.
- Clean all gearbox internals with solvent, dry and lightly coat contact faces with assembly grease recommended by the manual.

8) Reassemble shift mechanism
- Fit new or refurbished forks onto the synchronizer hubs. Ensure forks seat squarely on hub grooves. If forks have guide pins or shims, install as specified.
- Slide selector rails through forks in the correct order and orientation. You should feel forks engage into their gear hub grooves—do not force misaligned forks.
- Install retaining clips/circlips on rails/pins. Replace any one‑time clips. Torque rail retaining bolts per manual.

How to use specific tools during this operation
- Transmission jack: raise and lower gearbox evenly. Use straps/adapter to hold gearbox securely when removing or installing.
- Snap-ring pliers: compress or expand circlips when removing/installing nut-style rings on shafts; use the correct size tip to avoid deforming rings.
- Bearing puller/press: use puller to remove worn bearings from shafts; use press to install new bearings with steady, centered force to avoid shaft damage. Use correct bearing driver so force is applied to bearing outer race.
- Dial indicator: measure input shaft endfloat and gear backlash. Mount indicator on a fixed housing point and press indicator tip against shaft/gear; rotate and read runout/backlash. Compare to spec and adjust shims accordingly.
- Seal driver: install new seals squarely without cocking; drive on outer edge to avoid sealing lip damage.

9) Adjustment and checks before final assembly
- Check synchronizer hub engagement and free movement of forks on rails. Manually operate selector rails through all gear positions; ensure smooth movement without binding.
- Check axial endfloat on input/countershafts and backlash on gears per Hino specs with dial indicator. Fit any required shims if out of spec.
- Replace cover gaskets and seals, torque cover bolts to spec.

10) Reinstall transmission
- Lift gearbox with transmission jack, align with engine input shaft, support and mate to bellhousing. Refit bellhousing bolts and torque to Hino manual values.
- Reinstall clutch assembly if removed, align using pilot alignment tool. Refit all linkages, sensors, driveshafts, and electrical connectors.

11) Fill and test
- Refill gearbox to the correct level using manufacturer-specified gearbox oil.
- Before lowering vehicle, with truck still supported, run engine (if safe) and shift through gears to verify engagement and lack of unusual noises.
- Lower vehicle, road test under light load. Check for leaks, correct shifting, and normal operation. Recheck fluid level after warm-up.

Common pitfalls and how to avoid them
- Reusing worn forks or selector bushings — leads to rapid failure and poor shifting. Replace worn parts.
- Incorrect orientation/ordering of forks and rails — always mark parts during disassembly and reassemble in same sequence.
- Not checking synchronizer and hub wear — forks wear frequently due to hub damage; replace synchronizer components if worn.
- Forcing rails or forks into position — indicates misalignment or incorrect parts. Investigate before forcing.
- Reusing damaged circlips or snap rings — always replace if they deform or lose spring.
- Improper bearing/seal installation — using wrong driver or applying off-center force can destroy components.
- Not checking endfloat/backlash — can cause noise and premature wear if out of spec.
- Contamination — keep all internals and fluids clean. Dirt leads to accelerated wear.

Final notes
- Follow Hino 500 Series workshop manual for gearbox-specific diagrams, part numbers, and exact torque/endfloat/backlash specifications.
- If any unusual wear patterns are found (scoring, mushroomed teeth, heat discoloration), plan to replace the affected shafts/gears or the complete gearbox reman unit.
- If unsure about measuring/adjusting shims or endfloat, have the transmission inspected/assembled by a specialist or a dealer.

That covers the practical, shop‑level process for replacement of shift forks on a Hino 500 Series manual transmission.
rteeqp73

HINO 500 SERIES - Online Product Presentation

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