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Hummer H1 (2002+). Manual - part 142

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Axles, Suspension, and Frame 9-29

05745159

Figure 9-62: Axle Mounted In Holding Fixture

Position housing so cover faces up. Remove twelve bolts
and cover from housing (Figure 9-62).

Mark bearing caps and housing for assembly and remove
bearing caps (Figure 9-63).

Figure 9-63: Housing Spreader Mounting

Install axle housing spreader J–3409-01 into holes in axle
holding fixture adapters and install dial indicator J–8001
to read from each end of housing as shown. Then set dial
indicator at 0.020 in. (0.5 mm).

CAUTION: Over-tightening of axle housing spreader will
damage axle housing.

10. Spread housing 0.010 in. (0.25 mm) and remove dial

indicator.

11. Remove differential assembly, two bearing cups, and

shims from housing (Figure 9-64). Tag bearing shims and
bearing cups for assembly.

Figure 9-64: Differential Assembly

12. Relieve pressure on axle housing spreader and remove

from housing.

CAUTION: To avoid damage, do not chisel or wedge ring
gear from axle assembly.

13. Remove eight bolts and ring gear from differential

assembly (Figure 9-65).

Figure 9-65: Ring Gear Removal

14. Rotate housing 90 degrees. Secure cover to housing with

two bolts (Figure 9-66).

DIFFERENTIAL

AXLE

AXLE HOLDING

FIXTURE J–3409-01

COVER

HOUSING

BEARING CAP

AXLE

HOUSING

SPREADER

HOUSING

DIAL INDICATOR

J–24385-01

J–8001

SHIM

BEARING CUP

DIFFERENTIAL

BEARING

SHIM

AXLE HOUSING

HOUSING

ASSEMBLY

CUP

SPREADER J–3409-01

DIFFERENTIAL ASSEMBLY

RING GEAR

9-30

Axles, Suspension, and Frame

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Figure 9-66: Axle Housing

15. Remove pinion nut and pinion yoke from pinion gear.

16. Drive pinion gear out of front pinion bearing.

17. Remove cover, pinion gear, and collapsible spacer from

housing. Discard collapsible spacer.

18. Remove pinion seal and front pinion bearing from

housing. Discard pinion seal.

19. Rotate front of housing upward 90 degrees. Using driver

handle J–8092 and bearing cup remover J–21786, remove
pinion rear bearing cup and pinion depth shim from
housing (Figure 9-67).

Figure 9-67: Pinion Rear Bearing Cup Removal

20. Rotate housing 180 degrees. Using driver handle J–8092

and pinion front bearing cup remover J–21787, remove
front pinion bearing cup from housing (Figure 9-68).

Figure 9-68: Pinion Front Bearing Cup Removal

Figure 9-69: Differential Side Bearing Removal

COVER

PINION

COLLAPSIBLE

HOUSING

FRONT

PINION SEAL

PINION YOKE

PINION NUT

SPACER

GEAR

PINION

BEARING

DRIVER

BEARING CUP

REMOVER

PINION

PINION REAR

BEARING CUP

HOUSING

DEPTH

SHIM

HANDLE

J–8092

J–21786

DRIVER

HANDLE

BEARING CUP

REMOVER

HOUSING

PINION FRONT

BEARING CUP

J–21787

J–8092

DIFFERENTIAL

SIDE BEARING

DIFFERENTIAL

ASSEMBLY

DIFFERENTIAL

SIDE BEARING

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Axles, Suspension, and Frame 9-31

05745159

Figure 9-70: Pinion Bearing Removal

21. Remove two differential side bearings from differential

assembly (Figure 9-69).

22. Remove rear pinion bearing from pinion gear (Figure 9-70).

23. Remove bearing from output shaft (Figure 9-71).

Figure 9-71: Output Shaft Bearing Removal

Cleaning and Inspection

NOTE:

Clean all components. Examine for wear or damage

and replace if necessary.

Inspect housing and all threaded holes for damage. Repair
any damaged threads with thread repair inserts. Replace
axle assembly if housing is damaged (Figure 9-72).

Figure 9-72: Housing

NOTE:

Ring and pinion gears must be replaced as matched set.

Inspect splines and gear teeth on pinion gear and ring gear
for damage. Replace both pinion gear and ring gear if either
is damaged (Figure 9-73: and Figure 9-74:).

Figure 9-73: Ring Gear

Figure 9-74: Pinion Gear

Inspect splines and sealing surfaces on output flanges,
pinion yoke, and output shaft for damage (Figure 9-75)
through (Figure 9-77).

Figure 9-75: Output Flange

Figure 9-76: Pinion Yoke

Figure 9-77: Output Shaft

Inspect all bearings and bearing cups for damage
(Figure 9-78).

Figure 9-78: Bearing and Bearing Cup

Inspect differential assembly case for damage
(Figure 9-79).

PINION GEAR

REAR PINION BEARING

BEARING

OUTPUT SHAFT

BEARING

CUP

9-32

Axles, Suspension, and Frame

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Figure 9-79: Differential Assembly

Axle Assembly

NOTE: PINION DEPTH SETTING

: Pinion gear depth is the

distance from the end face of the pinion to the center line of the
output shafts. The dimension is controlled by shims between
pinion gear rear bearing cup and differential housing. The pin-
ion gear is etched with two identifying numbers. The first num-
ber identifies ring gear and pinion gear as a matched set, and
the second number represents pinion depth variance. The sec-
ond number is preceded by a plus (+) or minus (-) which repre-
sents the amount the gear set varies from the standard setting of
2.547 in. (6.46 cm). If using original gear set, use original pin-
ion depth shim as a starter shim and proceed to step 4.

Measure thickness of original pinion depth shim and
record for reference (Figure 9-80).

Figure 9-80: Pinion Depth Shim

Check pinion depth variance number marked on old and
new pinion gears and record (Figure 9-81). Refer to
Table 4.

Figure 9-81: Pinion Depth Variance Number

Location

NOTE:

If the old pinion is marked -3 and the new pinion is

marked +2, the procedure would be as follows: Refer to Old
Pinion Marking column at left side of table and locate -3 in this
column. Then read to right, across table, until under +2 in New
Pinion Marking column. The box where two columns intersect
is amount of shim thickness change required. In this case, the
number in the intersecting box is -0.005 in. (0.13 mm) which
represents the amount to be subtracted from the old shim thick-
ness. If the box number had been a (+) figure, this amount
would be added to the old shim thickness. The actual pinion
depth measurement must be performed and final shim thick-
ness adjusted as necessary. Pinion shims are available from
0.084-0.111 in. (2.13-2.82 mm) in increments of 0.0005 in.
(0.0127 mm).

Refer to Old and New Pinion Marking columns on pinion
variance table. Note on table where old and new pinion
depth variances intersect. This will determine amount to
be added or subtracted from original pinion depth shim for
desired pinion depth starter shim.

Rotate housing so front pinion bearing cup bore faces up
(Figure 9-82).

Figure 9-82: Pinion Front Bearing Cup

Installation

DIFFERENTIAL

ASSEMBLY

PINION GEAR

PINION DEPTH

VARIANCE

NUMBER

DRIVER

HANDLE

BEARING CUP

INSTALLER

PINION FRONT

BEARING CUP

HOUSING

J–8092

J–8611-01

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