Hummer H1 (2002+). Instruction - page 92
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Transmission/Transfer Case 5-167
®
05745159
Figure 5-118: Front Output Shaft Front Bearing
Installation
Figure 5-119: Front Output Shaft Seal Installation
Figure 5-120: Front Output Shaft Rear Bearing
Removal
Figure 5-121: Front Output Shaft Rear Bearing
Installation
TOOL
HANDLE
TOOL J–33833
J–8092
FRONT
OUTPUT
SHAFT
SEAL
TOOL J–38869
REAR CASE
FRONT OUTPUT
SHAFT REAR
BEARING
SLIDE HAMMER
TOOL
J–26369
J–2619-01
BEARING
TOOL
HANDLE
TOOL
J–33832
J–8092
5-168
Transmission/Transfer Case
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®
INPUT GEAR BEARING REPLACEMENT
1.
Remove old bearing from interior of front case as shown.
Use tool handle J–8092 and tool J–29170 (Figure 5-122).
2.
Install new bearing using tool handle J–8092 and tool J–
29170 (Figure 5-123). Seat bearing so locating ring is
firmly seated against case.
Figure 5-122: Input Gear Bearing Removal
Figure 5-123: Input Gear Bearing Installation
MAINSHAFT PILOT BEARING REPLACEMENT
1.
Remove pilot bearing from input gear with slide hammer
J–2619-01, and puller tool J–29369-1 (Figure 5-124). Sup-
port input gear on vise or over precut notch or hole in
workbench.
2.
Install new pilot bearing in gear with tool handle J–8092
and tool J–33829 (Figure 5-125). Seat bearing flush with
chamfer in bearing bore.
Figure 5-124: Removing Mainshaft Pilot Bearing
From Input Gear
Figure 5-125: Installing Mainshaft Pilot Bearing In
Input Gear
BEARING
TOOL HANDLE
TOOL
J–29170
J–8092
BEARING
LOCATION
RING
NEW
BEARING
TOOL HANDLE
J–8092
TOOL
J–29170
INPUT
GEAR
TOOL
J–29369-1
SLIDE
HAMMER
J–2619-01
INPUT GEAR
TOOL
TOOL HANDLE
J–8092
J–33829
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Transmission/Transfer Case 5-169
®
05745159
EXTENSION HOUSING BUSHING AND SEAL
REPLACEMENT
1.
Remove old seal with pry tool.
2.
Drive out old bushing with tool handle J–8092 and tool J–
33839 (Figure 5-126).
3.
Position new bushing on tool J–33839 and tap bushing
into place until flush with bushing bore.
4.
Install new seal in housing with J–33843 or suitable size
installer tool (Figure 5-127).
5.
Lubricate seal lip with Dexron III or petroleum jelly.
Figure 5-126: Extension Housing Bushing
Replacement
Figure 5-127: Extension Housing Seal Installation
Figure 5-128: Rear Thrust Washer Installation
Figure 5-129: Input Gear Installation
TOOL
HANDLE
TOOL
J–33839
TOOL
HANDLE
TOOL
J–33839
NEW
BUSHING
INSTALLATION
REMOVAL
J–8092
J–8092
NEW SEAL
EXTENSION
HOUSING
SUITABLE SIZE
SEAL INSTALLER
J–33843 OR
LOW RANGE
PLANETARY
REAR THRUST
WASHER
LOW
RANGE
PLANETARY
INPUT
GEAR
5-170
Transmission/Transfer Case
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®
TRANSFER CASE ASSEMBLY
1.
Assemble input gear and low range planetary:
a.
Lubricate gear, planetary, and thrust washers with
Dexron III.
b.
Install rear thrust washer in planetary. Be sure washer
tabs are aligned in planetary notches as shown
(Figure 5-129)
NOTE:
The thrust washers are the same size and are inter-
changeable. Either washer can be used at the front or rear.
c.
Install input gear in planetary (Figure 5-130).
d.
Install front thrust washer. Be sure washer tabs are
seated in planetary notches as shown (Figure 5-130).
e.
Install lock ring (Figure 5-131) and lock ring retainer
(Figure 5-132).
2.
Lubricate shift sector shaft and install sector in case
(Figure 5-133).
3.
Install input gear/planetary assembly in front case
(Figure 5-134). Use wood hammer handle to tap input
gear shaft through bearing.
4.
Install input gear snap ring (Figure 5-135).
5.
Install front retainer as follows:
a.
Install new seal in retainer with tool J–33831
(Figure 5-136).
b.
Apply 3/16 in. (5 mm) bead of Loctite 518, Permatex
Ultra Black, or Ultra Copper to sealing surface of re-
tainer.
c.
Align oil feed slot in retainer with feed hole in front
case and install retainer (Figure 5-137).
d.
Install and tighten retainer bolts to 12-18 lb-ft (16-24
N•m).
Figure 5-130: Front Thrust Washer Installation
Figure 5-131: Lock Ring Installation
Figure 5-132: Input Gear Snap Ring Installation
6.
Assemble low range fork and hub. Replace pads on fork if
worn or damaged (Figure 5-138).
7.
Install low range fork and hub. Be sure hub is seated in
planetary and that fork pin is seated in shift sector lower
slot (Figure 5-139).
FRONT
THRUST
WASHER
LOW RANGE
PLANETARY
INPUT GEAR
LOCK RING
LOCK
RING
RETAINER