Hummer H1 (2002+). Manual - part 152

________________________________________

 Axles, Suspension, and Frame  9-69

®

05745159

Straightening

1.

When performing straightening repairs with the frame on 
the vehicle:

• Use spreader plates or wood blocking to distribute chain 

force to avoid damage to frame box section.

• Be sure to loosen sufficient length of frame to allow 

frame force points to move without causing other dam-
age.

• Restrain vehicle movement in both directions along line 

of force application.

2.

Vertical bends, except at end sections, require removal of
frame rail from vehicle.

3.

Application of bulk heating to frame components is not
authorized, metal properties will be irreversibly degraded.

4.

At the conclusion of a bend repair, carefully inspect welds
in the vicinity of repair and area of force application. Any
evidence of cracking or chipping of welds must be
repaired.

Figure 9-157:   Frame Dimensions

MEASURE FROM CENTER 

OF BODY MOUNT

BRACKET HOLES

72.304-72.124 

INCHES

49.150-48.850

INCHES

77.026-76.466

INCHES

29.30-29.06 

INCHES

MEASURE FROM OUTSIDE

EDGE OF FRAME RAILS

MEASURE FROM CENTER 

OF BODY MOUNT

BRACKET HOLES

9-70

Axles, Suspension, and Frame

_________________________________________

®

WINCH  (OPTION) PRIOR TO VIN 186477

Winch Troubleshooting

Winch Inoperative

1.

Check for jammed winch cable.

2.

Check winch control cable connector for corrosion or
loose connection. Clean corroded connector or secure
loose connection.

3.

Check for loose or damaged winch power cables. Using
voltmeter, connect positive meter lead to positive power
cable (red) at the winch motor, and negative meter lead to
the winch motor ground cables (black). If voltage is not
present, repair or replace winch power cables.

4.

Disconnect winch control from winch. Using an
ohmmeter, check for continuity between the common
terminal and the other two terminals on winch control
cable connector. Check for continuity one at a time, while
holding control in the OUT position and IN position. If
continuity is present in both positions, repair winch. If
continuity is not present in both positions, replace winch
control.

Winch Replacement

Removal 

WARNING:  To avoid personal injury or damage, sup-
port winch during removal.

1.

Disconnect battery ground cables (Section 12).

2.

Remove two battery cable bolts, battery cables, and winch
cables from battery  (Figure 9-158).

Figure 9-158:    Winch Cables On Battery 

3.

Remove nut, lockwasher, capscrew, and clamp from right
frame extension. Discard lockwasher. Pull winch cables
through the splash shield to front of vehicle
(Figure 9-159). 

Figure 9-159:   Frame Bracket

4.

Remove four nuts, washers, bolts, and winch from front
bumper (Figure 9-160).

Figure 9-160:    Winch and Winch Cables 

POSITIVE

BATTERY

NEGATIVE

POSITIVE

BATTERY CABLE

 BATTERY 

CABLE

 WINCH 

CABLE

NEGATIVE

WINCH CABLE

BATTERY CABLE

BOLTS

CLAMP

FRAME BRACKET

POWER CABLES

CLAMP

POSITIVE 

CONTROL 

NEGATIVE

FRONT BUMPER

WINCH

NUT

BOX 

COVER

WINCH 

CABLE

 WINCH 

CABLE

________________________________________

 Axles, Suspension, and Frame  9-71

®

05745159

5.

Remove two bolts and clamps securing winch cables to
winch.

6.

Remove three bolts and control box cover from winch.

NOTE: 

It may be necessary to remove plastic coating com-

pound from winch in order to perform steps 7 and 8. 

7.

Remove capscrew, washer, and negative winch cable from
winch.

8.

Remove locknut and positive winch cable from winch.
Discard locknut.

Installation 

NOTE: 

Positive winch cable must be positioned to align with

the opening in the control box cover. 

1.

Install positive winch cable on winch with locknut 
(Figure 9-160).

2.

Install negative winch cable on winch with washer and
capscrew.

3.

Coat motor end of winch with coating compound. 

4.

Install control box cover on winch with three bolts.

5.

Secure two winch cables to winch with two clamps and
bolts. 

6.

Install winch on front bumper with four washers, bolts,
and nuts. Tighten bolts to 60 lb-ft (81 N•m).

7.

Route winch power cables through the splash shield.

8.

Install winch cables on frame bracket with clamp,
capscrew, lockwasher, and nut (Figure 9-159).

9.

Connect battery ground cables (Section 12).

Winch Cable Replacement 

WARNING:  To avoid injury, wear gloves when han-
dling winch cable.

Removal 

1.

Unwind winch cable.

2.

Remove set screw and winch cable from drum assembly
(Figure 9-161).

3.

Remove cotter pin, clevis pin and hook from winch cable.
Discard cotter pin.

Figure 9-161:   Winch Cable 

Installation 

1.

Install hook, clevis pin and cotter pin on winch cable.

2.

Install winch cable on drum assembly with set screw.

CAUTION:  Install winch cable on drum under a load of at
least 500 lb (227 kg), or outer wraps will draw into
 inner wraps and damage cable.

NOTE: 

Spool winch cable according to rotation label on

winch or brake will not function.

3.

Rewind and lubricate winch cable.

SET SCREW 

COTTER PIN

HOOK

ROPE ANCHOR

WIRE ROPE 

ASSEMBLY

CLEVIS 

PIN

9-72

Axles, Suspension, and Frame

_________________________________________

®

Winch Assembly Repair

Disassembly 

1.

Remove winch and winch cable.

NOTE: 

Tag leads for assembly.

NOTE: 

It may be necessary to remove plastic coating from

winch in order to perform steps 2 through 5.

2.

Remove three nuts and control leads from motor
 (Figure 9-162).

Figure 9-162:    Control Leads 

3.

Loosen clamp and remove control from motor
(Figure 9-163).

Figure 9-163:    Control Unit 

4.

Remove clamps from motor.

5.

Mark motor end drum support, gear train assembly, and
gear end drum support for assembly (Figure 9-164).

Figure 9-164:    Drum Support and 

Gear Train Assembly

6.

Remove six bolts, three tie rods, motor end and gear end
drum supports from winch.

7.

Remove motor, and motor end drum support from drum
assembly. 

8.

Remove motor brake driver and spacer from motor shaft.

9.

Remove drum assembly from gear train assembly
(Figure 9-164).

10. Remove two nylon thrust washers from drum

(Figure 9-165).

Figure 9-165:   Thrust Washers and Brake

LEAD

CONTROL

CLAMP

DRUM SUPPORT

NUT

MOTOR

CONTROL

CLAMP

MOTOR

MOTOR

(SHOWN WITHOUT CONTROL)

SPACER (2)

DRUM SUPPORT

BRAKE 

BRAKE 

DRUM

ASSEMBLY

DRIVER

 MOTOR END

DRUM SUPPORT

 MOTOR END

TIE ROD

GEAR TRAIN

ASSEMBLY

NYLON THRUST

WASHER

BRAKE 

DRUM

NYLON THRUST

WASHER

SET SCREW

BRAKE RETENTION

NOT REMOVABLE

BEARING

TOLERANCE 

RING

ASSEMBLY