Hummer H1 (2002+). Instruction - page 92

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Transmission/Transfer Case 5-167

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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

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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

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