Tools & consumables
- Heavy-duty floor jack (2–3 ton) and axle/transmission jack or engine hoist for leaf pack handling
- Quality jack stands (rated for GVW of vehicle) — 4 stands
- Wheel chocks, blocks
- Socket set (impact and hand): 17–36 mm (common truck sizes), deep sockets
- Breaker bar 1/2" & 3/4" drive
- Torque wrench (capable up to 600 Nm)
- Impact gun (air or electric) for removing nuts (use carefully)
- Pry bars, large screwdrivers
- Hammer, punch/chisel
- Spring vise or C-clamp for minor spring tension control (if applicable)
- Hydraulic press or bushing driver kit (for replacing bushings)
- Penetrating oil (PB Blaster), wire brush, grinder (for cleaning)
- Replacement U-bolts with new nuts & plates (recommended)
- New leaf spring pack (or individual leaves if staged repair)
- New spring eye bushings, shackle pins & bushings, spring-to-spring band and center bolt (replace all worn components)
- Anti-seize compound, thread locker (per manual), chassis grease
- Safety glasses, gloves, steel-toe boots
- Torque values / workshop manual for Hino FG17/FG19 (consult OEM manual for exact specs)

Safety precautions (non‑negotiable)
- Park on level, solid surface. Chock front wheels and set parking brake.
- Never rely on a jack alone — always support vehicle on rated jack stands positioned under the frame.
- Support the axle with a transmission/axle jack to carry suspension load while removing fasteners.
- Leaf packs are heavy and can release stored energy — control them with a second jack, chain, or hoist before releasing U-bolts or shackles.
- Wear eye protection and gloves. Keep clear of pinch points.
- If a spring is cracked or broken, don’t attempt to cut or temper it on the vehicle; remove and handle it with controlled lifting gear.

Parts typically required
- Complete replacement leaf spring pack (OEM part for FG17/FG19 or equivalent)
- New U-bolts, plates and nuts (always replace)
- Spring eye bushings and shackle pins (replace if worn)
- Center bolt and spring band (replace if bent/worn)
- Shackle bushings/hangers (if worn)
- Any worn hanger brackets, spring perches/pads — inspect and replace if damaged

Step-by-step procedure (rear leaf spring typical — front similar with additional steering/brake considerations)

1. Preparation
- Read Hino FG17/FG19 workshop manual for model-specific details and torque specs.
- Chock front wheels, put transmission in neutral (or PARK for automatic), set parking brake.
- Loosen rear wheel lug nuts slightly if wheel removal required.

2. Raise and support vehicle
- Raise the rear with floor jack under axle differential or axle tube. Place jack stands under the frame rails, forward and rear of the work area. Lower vehicle onto stands.
- Place a transmission/axle jack under axle directly beneath the spring seat. Raise jack to take load so axle is supported and springs are slightly unloaded but still in position.

3. Remove wheels (if necessary)
- Remove wheels to gain full access to U-bolts, hangers and shock absorbers.

4. Disconnect auxiliary components
- Remove or disconnect any brake lines, ABS sensor brackets, shock absorbers, bump stops or airbag links that interfere with spring removal. Support brake lines with wire to avoid strain.
- Mark and remove any sway bar or radius rod connections attached to the axle/springs.

5. Support and relieve spring tension
- Ensure axle jack supports full weight of axle. Do not remove U-bolts while axle is unsupported.
- If spring is under slight load, use a second jack, chain or hoist to control the spring pack and prevent sudden drop.

6. Remove U-bolts and spring plate
- Spray penetrating oil on U-bolt nuts. Use impact or breaker bar to remove nuts. If studs are corroded, cut nuts off carefully with grinder (protect components).
- Remove lower U-bolt plate and U-bolts and let axle slide away slightly on jack so the spring pack can be dropped.

Tool use note: Impact gun speeds removal but be cautious — it can snap studs or damage threads. Use breaker bar for stubborn nuts; heat only if safe and not near fuel/brake lines.

7. Remove spring-to-axle mounting and shackles
- Remove center bolt that clamps leaves together (punch out if corroded).
- Remove spring-to-spring band (if present).
- Remove front or rear eye bolt/shackle pin. Use penetrating oil, a drift and hammer; support the leaf pack so it doesn’t fall when shackles are free.
- Remove spring from hanger by easing it down off the perch. Use pry bar to free spring eyes if rust-bound.

8. Remove spring assembly from vehicle
- Use axle/transmission jack or hoist to lower spring pack completely and remove. Have an assistant or secondary support to control the weight.

9. Inspect mountings & replace bushings/hardware
- Clean spring perch, hanger, shackle, axle saddle and contact faces with wire brush; remove rust and paint build-up.
- Measure hanger bores and shackle eyes for ovality. Replace worn hangers/shackles.
- Press out old bushings using hydraulic press or bushing driver. Install new bushings with press or correctly sized driver. Use chassis grease where specified by manual (many bushing types are greased, others are dry — follow manual).

Tool use note: Hydraulic press or bushing driver — align bushing and drive squarely, support the housing. Heat to ~120–150°C can ease install for metallic sleeves if permitted. Never hammer bushing in cocked — it damages the bushing.

10. Fit new leaf pack
- Position new leaf spring pack on axle saddle: center the center bolt in the axle seat and on the perch.
- If the leaf pack has a marked front, orient correctly (concave up vs down). New spring arch orientation matters — ensure it matches old part.

11. Reinstall U-bolts & hand-tighten nuts
- Fit new U-bolts and plate. Tighten nuts by hand initially to keep assembly captive.
- Reinstall shackles, shackle pins and fit new bushings/grease. Apply anti-seize on shackle threads if recommended.

12. Lower axle onto springs and torque U-bolts
- Slowly lower axle jack so the axle rests on the spring without the full vehicle weight yet. Make sure alignment of center bolt and spring seat is correct.
- Torque U-bolts and shackle pins to Hino specified values (important). If you don’t have exact specs, consult the Hino workshop manual—do not guess.

Torque note: For FG medium trucks, U-bolt torque is high — use a torque wrench rated for the value and a 3/4" drive if required.

13. Reattach brakes, shocks and ancillary parts
- Reattach shocks, brake lines, ABS brackets, bump stops and any sway or radius rods removed earlier. Replace any worn hardware.
- Ensure brake lines are not twisted and have proper slack through full suspension travel.

14. Refit wheels, lower vehicle and final torque
- Reinstall wheels, lower vehicle to ground carefully. With vehicle on level ground and normal weight on suspension, torque U-bolts, axle saddle nuts and shackle hardware to final spec.
- Re-torque wheel lug nuts to spec.

15. Test & break-in checks
- Drive short test route at low speed checking for clunks, noise, sag or misalignment.
- Recheck torque of U-bolts and shackle nuts after 50–100 km or after initial heavy loading. Inspect for leaks, rubbing, or worn parts.

Common pitfalls & how to avoid them
- Removing U-bolts with axle unsupported: can cause sudden drop and injury. Always support axle with jack/hoist.
- Reusing U-bolts and old hardware: salvage U-bolts may be fatigued and stretch — replace them.
- Incorrect spring orientation or mixing old/new springs: mix-matched arch heights cause ride and axle alignment issues. Install matching pack set.
- Not replacing bushings/shackle pins: worn bushings lead to noise, misalignment and accelerated wear.
- Over-tightening U-bolts with vehicle on stands (not on tires): torque must be done with vehicle weight on springs unless manual directs otherwise.
- Ignoring hanger/shackle wear: worn hangers will quickly destroy new bushings and springs.
- Failing to consult OEM specs: torque values, bushing type (greased vs dry) and assembly order are manufacturer-specific — always verify with Hino WSM.

Final notes
- Always follow Hino FG17/FG19 workshop manual for exact torque values, part numbers and any special procedures (anti‑corrosion coatings, specific grease types, or orientation marks).
- After replacement, observe vehicle load distribution and recheck mounting hardware after initial use.

End.
rteeqp73

From the Archives: Hino FG Series Old footage of the Hino FG Series truck.

From the Archives: Hino FG Series Old footage of the Hino FG Series truck.

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