Below is an ordered, theory‑focused workshop procedure for replacing the transmission pump on a Hino 500 series (automatic transmission). This is written as a technician’s sequence with why each action matters and how the repair corrects common faults. Use the OEM manual for model/year‑specific torque values, hydraulic specs, and fluid type.

Safety & prep
1. Safety, PPE, and isolation
- Action: Park on level surface, chock wheels, isolate battery, support vehicle with rated stands, relieve system pressures.
- Theory: Prevents uncontrolled vehicle movement and electric/hydraulic hazards. Residual pressure in the transmission hydraulic circuit can spray fluid or cause parts to move.

2. Tools, parts, and cleanliness
- Action: Prepare service manual, pressure gauge kit, clean work area, new pump or pump kit (rotor/gears/seals), new gaskets/O‑rings, filter, recommended fluid, torque wrench and lifting gear.
- Theory: Hydraulics require cleanliness and correct clearances; contaminated components or wrong parts will cause repeat failure.

Confirm pump is the fault (diagnosis before removal)
3. Symptom check and pressure test
- Action: Verify symptoms (low line pressure, slipping/harsh shifts, slow engagement, whining at idle). Hook up line pressure gauge(s) to the transmission test ports and read pressures at idle and with applied load per manual.
- Theory: The pump’s role is to generate hydraulic pressure and flow. Low/no line pressure or unstable pressure under load isolates the pump as cause; symptoms alone aren’t conclusive.

4. Filter/strainer inspection and fluid analysis
- Action: Remove pan/filter (if accessible) and inspect for metal particles, scoring, burnt smell, or coolant. Check fluid level and condition.
- Theory: Metal in the filter indicates internal wear (pump or gears). Burnt fluid means overheating. Contamination can damage a new pump, so diagnosis must include contamination source.

Removal and access
5. Drain fluid and prepare for contamination control
- Action: Drain ATF into clean containers; cap lines to prevent dirt ingress.
- Theory: Minimizes contamination when opening the system and lets you inspect fluid for debris severity.

6. Disconnect external items
- Action: Remove drive shafts, cooler lines, electrical connectors, shift linkage, and any brackets blocking transmission access.
- Theory: Necessary to access the transmission housing safely and avoid damage to peripherals.

7. Support and separate transmission (as required)
- Action: Support transmission with a jack or hoist. Depending on pump location (case-mounted), you may need to remove the transmission from the vehicle or separate the torque converter/adapter housing.
- Theory: Pump replacement often requires access to the front case or removal of one case half; correct support prevents misalignment and injury.

Pump removal
8. Access pump housing
- Action: Remove bellhousing/front cover or front pump cover bolts and remove cover to expose pump assembly.
- Theory: Transmission pumps are typically mounted in the front case; removing the cover exposes pump gears/rotors.

9. Photograph/mark orientation and routing
- Action: Mark positions of pump housing, dowels, and mating surfaces; photograph as reference.
- Theory: Correct reassembly orientation is crucial for timing/gear alignment and preventing leaks.

10. Remove pump assembly
- Action: Unbolt and withdraw the pump (gear/rotor assembly) and any associated valve or relief components; remove seals and O‑rings.
- Theory: Extracting the pump allows inspection of internal clearances and wear patterns which indicate failure mode (e.g., rotor wear, scoring).

Inspection and prepare replacement
11. Inspect mating surfaces and bearings
- Action: Inspect pump bore, shaft, bearings, cam ring, and case for scoring, ovality, or metallurgy debris.
- Theory: Pump failure often wears the bore or shaft; simply fitting a new pump into a damaged bore will quickly fail. Detecting wear determines whether case machining or replacement is needed.

12. Measure clearances
- Action: Measure rotor/cam clearances and shaft endplay per manual.
- Theory: Correct clearances control volumetric efficiency and pressure generation. Excessive clearance => low pressure / cavitation.

13. Clean or replace bearings/seals
- Action: Replace worn bearings, seals, and O‑rings; clean the case and hydraulic passages with lint‑free wipes and solvent.
- Theory: Bearings and seals maintain rotor concentricity and keep fluid in the circuit; damaged ones cause internal leaks and loss of pressure.

Install new pump
14. Prepare and install new pump assembly
- Action: Fit new pump components (or preassembled pump) with new gaskets/seals, ensuring correct orientation and dowel alignment. Use OEM shims if required to set endplay.
- Theory: New pump restores correct internal geometry for intended volumetric flow vs. shaft speed, producing required line pressure and flow.

15. Reassemble covers and torque fasteners
- Action: Fit covers and torque bolts to OEM specs, in the recommended sequence.
- Theory: Even torque prevents case distortion which can change clearances and create leaks.

Reassembly and system reconditioning
16. Reconnect external lines/filters
- Action: Reattach cooler lines, electrical connectors, shift linkage, and new filter and pan gasket if removed.
- Theory: Proper routing and sealing avoid external leaks and ensure correct cooler flow.

17. Refill with correct fluid and priming
- Action: Refill with OEM-specified fluid to the proper level. Prime pump if required (turn engine to fill pump while out of torque load) per manual.
- Theory: New pump must be primed to avoid dry starts and cavitation; correct fluid viscosity and level are required for intended flow and cooling.

Commissioning and verification
18. Static pressure and leak test
- Action: With engine running, measure line pressures at test ports and compare to manual values (idle, kickdown, WOT, gear conditions). Check for external leaks and examine fluid temperature rise.
- Theory: Confirms pump produces required pressure/flow under operating conditions and that valves/control circuits respond.

19. Dynamic road test and recheck
- Action: Run road test covering shift points and load ranges; recheck fluid level and filter for new debris.
- Theory: Under load verifies pump performance in real conditions; a final fluid/strainer check ensures no remaining debris will damage new pump.

How the repair fixes the fault (theory)
- Pressure restoration: The pump generates hydraulic pressure and flow that operate clutches, bands, and valve bodies. A worn or damaged pump leaks internally (volumetric loss) and cannot maintain line pressure. Replacing the pump restores volumetric efficiency so the hydraulic circuits see correct pressure and shifts engage properly.
- Flow stability and cooling: A healthy pump provides steady flow to the cooler and torque elements. Replacing a failing pump restores flow, reduces overheating/cavitation and eliminates aeration/foaming that causes erratic operation.
- Elimination of metal contamination source: Pump wear often creates metal debris that damages valves and servos. Replacing the pump removes the debris source; cleaning the circuit/filter prevents re‑wear of the new pump and control components.
- Correct clearances and sealing: New rotors/gears and seals restore internal sealing surfaces and clearances so pressure is built where intended rather than being lost across worn gaps.
- Prevents secondary failures: A failing pump can cause overheating and burnt fluid, which degrades seals and friction materials. Replacing the pump and refreshing fluid stops ongoing degradation.

Common failure modes you fix by this job
- Low/no line pressure under load (pump wear/clearance loss)
- Whining or aeration noises at idle (cavitation, low fluid/air ingress)
- Slow or slipping engagements (inadequate pressure)
- Metal in filter/pan (pump gear wear)
- Intermittent shifting or no reverse (pump internal leaks or relief valve failure)

Final notes (concise)
- Always use OEM fluid and torque specs; incorrect fluid viscosity or torque changes can cause immediate failure.
- If severe contamination or case damage is found, replace or machine the case and flush the cooler lines before installing a new pump.
- After replacement, monitor fluid temperatures and pressure for several hours/miles to ensure no recurrence.

No questions.
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