Ordered, theory‑focused overview of overhauling the gearbox (gear set) on a Toyota Hiace (manual transmission). Each step explains what you do and why — how that action corrects the fault.

1) Define scope & symptoms (diagnose before teardown)
- What you observe: whining/whirring (bearing/gear misalignment), clunking or crunching on shifts (damaged teeth or worn synchros), slipping or hard engagement (synchro/selector problems), leaks (seal/gasket failure), excessive play (bearing wear/shims).
- Why: correct diagnosis focuses the overhaul on the worn subsystem (bearings, gears, synchros, shims) so you don’t replace good parts or miss root causes.

2) Remove gearbox as an assembly (conceptual)
- Purpose: gain full access to internal shafts and bearings so measurements can be made. The gearbox must be out to control axial/preload settings and to inspect tooth contact under controlled conditions.

3) Clean, tag and record baseline settings
- Theory: mark positions of shims, flange orientations and linkage locations. Many faults are caused by wrong shim/thrust settings on reassembly; recording original setup gives a baseline for correct re‑assembly or deliberate correction.

4) Systematic disassembly, preserving measuring surfaces
- What you do conceptually: strip covers, remove shafts and bearings in order so components and raceways remain identifiable.
- Why: preserves reference geometry. Controlled disassembly lets you assess wear patterns on mating parts (which show cause and direction of failure).

5) Visual and dimensional inspection — detect failure modes
- Visual cues and their meanings:
- Polished, grooved or pitted tooth flanks → improper lubrication, contamination or contact pattern error.
- Chipped/broken teeth → shock overload or fatigue.
- Burnished, blued, or scored surfaces → overheating/insufficient oil film.
- Worn synchro rings (rounded friction surfaces) → loss of synchronizing friction → grinding.
- Cup/cone bearing roughness or radial play → whining or gear runout.
- Dimensional checks (tools: micrometer, dial indicator, inside mic, feeler gauges/plastigauge):
- Shaft runout, spline wear, tooth thickness, bearing inner/outer race clearances, endfloat.
- Why: distinguishing worn components that must be replaced from serviceable items prevents re‑installation of failed elements that will re‑cause symptoms.

6) Bearings: replace and set preload/endfloat
- Theory: bearings locate shafts and carry radial and axial loads. Bearing wear increases play and changes gear mesh alignment, causing noise, accelerated tooth wear and loss of gear contact pattern.
- Repair action: replace worn bearings and races, then set bearing preload or shaft endfloat to spec (shims or preloads). Correct preload minimizes axial play and ensures bearings support gears at intended positions, restoring designed load distribution.

7) Gear tooth geometry and backlash/contact pattern correction
- Theory basics:
- Backlash is the circumferential play between mating gears. Too little = binding/heat; too much = impact/noise and accelerated wear.
- Pinion (or countershaft) depth controls where the tooth contact pattern sits across the gear flank. Proper depth centers the contact area so load is spread, not concentrated on a small area.
- Contact pattern verification (prussian blue or marking compound) shows where teeth mesh under load.
- Repair action: if gears are serviceable, adjust pinion depth and backlash (shims or carrier bearing location) until contact pattern is centered and backlash is within spec. If teeth are chipped, pitted, or severely worn, replace the gear(s).
- How it fixes fault: correct backlash and contact pattern reduce noise, prevent edge loading and pitting, and restore expected load capacity and life.

8) Synchros, sliding sleeves and selector components
- Theory: synchro rings provide friction to equalize input speeds before the dog engagement; blockers prevent sleeve engagement until speed is matched. Worn friction or damaged keys/springs prevents synchronization and causes grinding or hard engagement.
- Repair action: replace worn friction rings, worn keys or springs, and any damaged sliding sleeves; check and restore axial clearances.
- How it fixes fault: restores the friction surface and engagement geometry so gears synchronize smoothly, eliminating shift grinding and reducing wear from clash engagement.

9) Shafts, splines and keyways
- Theory: worn splines cause free play and misalignment under torque; fretting or galling accelerates wear of hubs and sleeves.
- Repair action: measure runout and spline wear; replace bent shafts or heavily worn splines; if minor, clean and apply correct tolerances; replace coupling components as needed.
- How it fixes fault: restores concentricity and proper coupling so torque transmits without added movement or shock loading.

10) Replace seals, gaskets and clean lubrication passages
- Theory: contamination and oil loss cause lubrication failure, which is the most common root of gearbox damage. Small particles cause fretting and accelerated wear.
- Repair action: fit new seals and gaskets, clean passages and magnet if present, ensure breathers are clear.
- How it fixes fault: prevents ingress of contaminants and maintains correct lubricant film to protect gears/bearings.

11) Reassembly with attention to torque, preload and measurement
- What to set:
- Bearing preload/endfloat per spec.
- Backlash and pinion/carrier depth to achieve correct contact pattern.
- Torque of retaining nuts/bolts to avoid distortion that alters alignment.
- Why: correct torques and shims lock-in the geometry that gave the verified contact pattern; incorrect tightening shifts geometry and re-introduces faults.

12) Verify contact pattern, backlash and free rotation before installation
- Theory: verifying these off the vehicle ensures that the internal geometry and mesh are correct; it's much easier to correct a shim than to fight it after installation.
- Action: run the input through, check patterns with marking compound under light load, measure backlash with dial indicator and endfloat; make iterative shim adjustments until patterns and clearances are correct.

13) Final fitment, fill with specified gear oil, run-in and test
- Why run-in: new friction surfaces and bearings bed in; early run-in allows detection of setup problems under controlled conditions.
- Test actions: static rotation checks, idle vibration test, road test under progressive load. After initial run-in, recheck torque and clearances.

14) How each repair action fixes the common faults (summary mapping)
- Whine/whirring at specific gear speeds → bearing replacement / preload, correct mesh/backlash.
- Grinding during shifts → replace synchros/keys/springs, restore synchronizer clearances.
- Clunk on engagement or loose feeling → worn splines, excessive backlash, worn engagement dogs; replace worn components and set backlash.
- Heat/scoring/pitting → remedy by replacing damaged gears, ensuring correct lubrication, restoring contact pattern and removing root contamination sources.
- Oil leaks → new seals/gaskets and correct installation torque.

15) Tools, measurements and reference data to use
- Essential measuring tools: micrometer, dial indicator, bore gauge, plastigauge or feeler gauges, torque wrench, marking compound for contact pattern.
- Always use Toyota service manual specs for backlash, pinion depth, shim thicknesses, bearing preload and torque values. These specs determine correct tolerances; the theoretical principles tell you what to adjust and why.

Keep in mind: the theory governs the adjustments — bearings locate shafts, shims set gear depth/backlash, synchros provide friction synchronization, seals keep lubricant in and contaminants out. An overhaul replaces failed load-bearing or friction parts and restores the designed geometry so load is properly distributed and the gearbox regains quiet, durable operation.
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