Hummer H1 (2002+). Manual - part 140

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 Axles, Suspension, and Frame  9-21

®

05745159

GEARED HUB SPINDLE STUD REPLACEMENT

WARNING:   Always wear eye protection when replac-
ing spindle studs. Severe eye injury may result if metal
chips contact eyes.

Removal 

1.

Remove wheel. 

2.

Rotate spindle to allow clearance for removal of stud from
spindle (Figure 9-44).

3.

Drive stud from spindle. Discard stud.

Figure 9-44:   Geared Hub Spindle Stud Removal

Installation 

1.

Install stud in spindle (Figure 9-44).

2.

Install three flat washers and hex nut on stud.

3.

Tighten hex nut until head on stud seats against spindle.

4.

Remove and discard hex nut and three flat washers.

HALFSHAFT BOOT REPLACEMENT

Removal 

NOTE: 

Inner and outer boots are replaced together. The inner

CV joint is disassembled to gain access to the halfshaft boots.

1.

Remove wheel.

2.

Remove access plug and washer from geared hub
(Figure 9-45).

3.

Remove six bolts, lockwashers, and halfshaft from rotor.

4.

Remove halfshaft retaining bolt, lockwasher, and halfshaft
from geared hub.

Figure 9-45:   Halfshaft Retaining Bolt

5.

Loosen two clamps securing inner boot to inner joint
housing and shaft (Figure 9-46).

6.

Slide inner boot toward outer joint along shaft.

NOTE: 

 Remove excess grease from bearing assembly.

7.

Clamp shaft in soft-jawed vise.

8.

Remove retaining ring from inner joint housing by forcing
clip up chamfer on inside of housing.

9.

Remove housing and six ball bearings from bearing
assembly.

10. Move outer race up on shaft to allow for better access to

inner race (Figure 9-48).

11. Locate snap ring adjacent to inner race. Remove snap ring

from groove and slide up on shaft  (Figure 9-48).

12. Tap inner race up on shaft to expose retaining clip.

13. Remove retaining clip and inner race from shaft.

14. Remove outer race, snap ring, and inner boot from shaft.

(Figure 9-48).

15. Remove two clamps and outer boot from shaft.

Cleaning and Inspection 

NOTE: 

 Clean all components, examine for wear or damage,

and replace halfshaft if necessary.

1.

Clean all metallic parts with solvent.

2.

Inspect halfshaft assembly for damage or wear, and
replace if damaged or worn.

SPINDLE

STUD

ROTOR

HALFSHAFT

GEARED 

HALFSHAFT

ACCESS 

PLUG

HUB

 RETAINING

 BOLT

9-22

Axles, Suspension, and Frame

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®

Installation 

1.

Position outer boot and two clamps on shaft near outer 
joint.

2.

Apply packet of grease to outer joint.

3.

Position outer boot over outer joint housing and secure
clamp with boot banding tool J–22610.

4.

Secure smaller clamp on boot and shaft with tool J–22610.

5.

Clamp shaft in vise with protective jaws.

6.

Position two clamps on shaft (Figure 9-49).

7.

Install inner boot on shaft. Push boot past groove on shaft.

8.

Install the snap ring and retaining clip into grooves on
shaft  (Figure 9-48).

9.

Align chamfer splines of inner bearing assembly with
spline of shaft. Use press or rawhide hammer to install
inner race until it snaps in place - flush against spacer ring.

10. Position six ball bearings into bearing assembly and retain

with a slight amount of grease (Figure 9-46).

Figure 9-46:   Halfshaft Boot Replacement

Figure 9-47:   Halfshaft Boot Replacement

Figure 9-48:   Halfshaft Boot Replacement

Figure 9-49:   Halfshaft Boot Replacement

INNER JOINT HOUSING

RETAINING RING

BEARING

INNER BOOT

OUTER

RACE

INNER RACE

OUTER JOINT

RETAINING CLIP

SHAFT

INNER BOOT

OUTER RACE

SNAPRING

INNER RACE

BEARING

SNAP RING

SNAP RING

INNER BOOT

GROOVE

ASSEMBLY

RETAINING

CLIP

GROOVE

INNER BOOT

OUTER BOOT

OUTER

CV JOINT

ASSEMBLY

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 Axles, Suspension, and Frame  9-23

®

05745159

11. Position joint inner housing over bearing assembly.

NOTE: 

 Ensure all ball bearings are in the tracks of the inner

joint.

12. Secure retainer ring in groove of inner joint housing.

13. Fill inner joint with grease from grease packet.

14. Move inner boot on shaft until boot seats in groove of

shaft and inner joint housing.

15. Secure inner boot on shaft and housing with clamps.

Tighten clamps with crimping tool J–22610.

16. Slide halfshaft splines into geared hub.

17. Apply thread-locking compound to halfshaft retaining bolt

and secure halfshaft to geared hub with lockwasher and
halfshaft retaining bolt. Tighten halfshaft retaining bolt to
37 lb-ft (50 N•m) (Figure 9-45).

18. Install washer and access plug into geared hub. Tighten

access plug to 8-13 lb-ft (11-18 N•m).

NOTE: 

 Ensure all six bolt holes in the rotor align with holes

in output flange. Make sure mounting holes and bolts are
cleared of old Loctite.

19. Apply Loctite 272 to six bolts. Secure halfshaft to rotor

with twelve lockwashers and bolts. Tighten bolts to 48 lb-
ft (65 N•m).

20. Install wheel.

AXLE VENT LINE REPLACEMENT

NOTE: 

 Axle vent line replacement procedures are basically

the same. This procedure covers the rear axle vent line.

Removal 

1.

Disconnect vent line from axle fitting and tee fitting and 
remove vent line (Figure 9-50).

2.

Remove two line clips and vent line from brake line.

3.

Disconnect vent line from two tee fittings and remove vent
line.

Figure 9-50:   Axle Vent Line Location

Installation 

1.

Install vent line and connect to two tee fittings 
(Figure 9-50).

2.

Secure vent line to brake line with two line clips.

3.

Connect vent line to axle fitting and tee fitting.

LINE CLIPS

VENT LINE

TEE FITTING

BRAKE LINE

AXLE FITTING

VENT LINE

9-24

Axles, Suspension, and Frame

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®

GEARED HUB VENT LINE REPLACEMENT

NOTE: 

 All geared hub vent line replacement procedures are

basically the same. This procedure covers the right rear geared
hub vent line.

Removal 

NOTE: 

Speed sensor lead is retained by the vent line clamps

and should be removed and reinstalled with care when replac-
ing the vent line.

1.

Disconnect vent line from geared hub fitting (Figure 9-52).

2.

Remove bolt, clamp, and vent line from bracket.

3.

Remove bolt, clamp, and vent line from control arm.

4.

Remove bolt, clamp, and vent line from bracket.

5.

Remove bolt, clamp, and vent line from frame
(Figure 9-51).

6.

Disconnect vent line from tee fitting.

Installation 

1.

Secure vent line to frame with clamp and bolt  
(Figure 9-51).

2.

Secure vent line to bracket with clamp and bolt
(Figure 9-52).

3.

Connect vent line to tee fitting and geared hub fitting.

4.

Secure vent line to control arm with clamp and bolt
(Figure 9-52).

NOTE: 

Position clamp at a 45 degree angle toward the wheel

before securing with bolt.

5.

Secure vent line to bracket with clamp and bolt.

Figure 9-51:   Vent Line

Figure 9-52:   Geared Hub Vent Line Positioning

TEE FITTING

VENT LINE

FRAME

CLAMP

BRACKET

VENT

CONTROL ARM

CONTROL 

CLAMP

GEARED HUB

BRACKET

VENT

45°

 LINE

 FITTING

VENT LINE

 LINE

ARM