Content .. 151 152 153 154 ..

Hummer H1 (2002+). Manual - part 153

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Axles, Suspension, and Frame 9-73

05745159

11. Loosen set screw that retains brake.

12. Push brake through open end of drum and remove

(Figure 9-165).

13. Remove driveshaft from gear train assembly

(Figure 9-166).

14. Turn gear train assembly over with gear end drum support

down. Remove ten hex-head screws and gear housing
from gear end drum support.

15. Remove gasket from gear end drum support. Discard

gasket (Figure 9-166).

Figure 9-166: Gear Train Assembly

16. Remove detent spacer, spring, and detent ball from gear

housing (Figure 9-167).

Figure 9-167: Gear Housing

17. Remove clutch lever and O-ring seal from gear housing.

Discard O-ring seal.

18. Remove two retaining rings from gear housing

(Figure 9-167).

NOTE:

Intermediate ring gear comes out with 85 to 87 steel

balls. Be sure to catch all 85 to 87 steel balls.

19. Remove intermediate ring gear and 85 to 87 steel balls

from gear housing.

20. Remove input gear carrier assembly from gear housing

(Figure 9-167).

21. Remove intermediate gear carrier and output gear carrier

from output ring gear and gear end drum support
(Figure 9-168)

Figure 9-168: Gear Carriers

22. Remove output ring gear and gasket from gear end drum

support.

Cleaning

CAUTION: To avoid damage to equipment, do not clean brake
assembly. Clean and inspect all winch components. Replace
defective parts.

GEAR TRAIN ASSEMBLY

GASKET

GEAR HOUSING

DRIVESHAFT

GEAR END

DRUM SUPPORT

O-RING

CLUTCH

LEVER

DETENT

BALL

SPRING

DETENT

SPACER

STEEL BALLS

GEAR

RETAINING

RINGS

CLUTCH

RING

GEAR

SUN

INPUT

CARRIER

GEAR

HOUSING

INTERMEDIATE

GEAR CARRIER

OUTPUT GEAR

CARRIER

OUTPUT

RING GEAR

GASKET

GEAR END

DRUM SUPPORT

9-74

Axles, Suspension, and Frame

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Inspection

Inspect drum for damage to splined end flanges and tube
(Figure 9-169). Replace winch if damaged.

Figure 9-169: Drum Assembly and Gear Housing

Assembly

Inspect gear end and motor end drum supports for damage.
Replace if damaged.

Inspect gear housing for damage. Replace if damaged.

Inspect thrust plate for damage or wear. Replace if
damaged or worn. Apply grease on thrust plate for
assembly.

Inspect clutch lever and driveshaft for damage. Replace if
damaged.

Inspect gear teeth and machined surfaces of intermediate
ring gear for damage. Replace if damaged.

Inspect gear teeth, splines, and machined surfaces of
output ring gear, output gear carrier, intermediate gear
carrier, and input gear carrier assembly for damage.
Replace any damaged parts (Figure 9-170).

Figure 9-170: Gear Carriers

Inspect brake assembly for damage (Figure 9-171).

Inspect motor, spline, mating surface, and terminals for
damage. Replace motor if damaged (Figure 9-171).

Figure 9-171: Motor and Control Unit

10. Inspect cover for damage. Replace if damaged.

11. Inspect control for damaged leads, breaks in plastic

coating, and damaged mounting base. Replace control if
damaged or repair plastic coating.

MOTOR END

DRUM SUPPORT

DRUM

GEAR END

DRUM SUPPORT

DRIVE

SHAFT

GEAR

HOUSING

GASKET

THRUST

WASHER

THRUST

WASHER

OUTPUT

RING GEAR

OUTPUT

GEAR CARRIER

INTERMEDIATE

GEAR CARRIER

INPUT

GEAR CARRIER

ASSEMBLY

(THIRD STAGE)

ASSEMBLY

(SECOND STAGE)

(FIRST STAGE)

SUN

GEAR

COVER

LEADS

CONTROL

SPLINE

MOTOR

DRUM

SUPPORT

BALL

BEARING

SPACER

CLAMP

3-1-01

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Axles, Suspension, and Frame 9-75

05745159

Assembly

Position 85 to 87 steel balls in groove of intermediate ring
gear and install intermediate ring gear in gear housing
(Figure 9-172).

Figure 9-172: Intermediate Ring Gear and

Gear Housing

Install retaining rings in gear housing.

Apply light oil to steel balls through the clutch lever hole.

Apply grease to clutch lever hole and install O-ring seal
and clutch lever in gear housing.

Install detent ball, spring, and detent spacer in gear
housing.

Apply aircraft grease to output gear carrier, intermediate
gear carrier, and input gear carrier assembly (Figure 9-173).

Figure 9-173: Gear Carriers

Install input gear carrier assembly in gear housing.

NOTE:

Be sure ring gear engages in gear housing.

Install gasket and output ring gear on gear housing.

Install intermediate gear carrier on gear housing.

10. Install output gear carrier on intermediate gear carrier.

11. Install gasket on output ring gear (Figure 9-174).

Figure 9-174: Gear Train Assembly

NOTE:

Ensure spline on drum support engages in output ring

gear.

12. Install gear end drum support on output ring gear and gear

housing.

13. Secure gear housing assembly to drum support with ten

hex-head screws. Tighten hex-head screws to 100 lb-in.
(11 N•m).

14. Turn gear train assembly over with drum support facing

up.

15. Install driveshaft in gear train assembly (Figure 9-174).

16. Apply grease to drum bushings, seals, and output spline

(Figure 9-175).

Figure 9-175: Thrust Washers and Brakes

O- RING

CLUTCH

LEVER

DETENT

BALL

SPRING

DETENT

SPACER

CLUTCH

RING GEAR

RETAINING

RING

STEEL

BALLS

GEAR

HOUSING

SEAL

OUTPUT

GEAR

OUTPUT

RING GEAR

INTERMEDIATE

GEAR CARRIER

GASKET

INPUT

GEAR CARRIER

ASSEMBLY

GEAR

HOUSING

THRUST

WASHER

SUN

GEAR

CARRIER

GEAR TRAIN

ASSEMBLY

GASKET

DRIVE
SHAFT

GEAR END

DRUM SUPPORT

OUTPUT

RING GEAR

GEAR

HOUSING

NYLON THRUST

WASHER

BRAKE

DRUM

NYLON THRUST

WASHER

SET SCREW

BRAKE RETENSION

NOT REMOVABLE

BEARING

TOLERANCE

RING

ASSEMBLY

9-76

Axles, Suspension, and Frame

_________________________________________

17. With drum horizontal, install brake into drum.

18. Tighten brake retaining set screw to 18-22 ft-lb (24-30

N•m) torque.

19. Install two nylon thrust washers on drum.

20. Install drum assembly on gear train assembly. Rotate drum

assembly as needed to engage driveshaft, brake, and
output spline (Figure 9-176).

Figure 9-176: Drum Assembly and Gear

Train Assembly

21. Install brake drive and spacer to motor shaft.

22. Install motor end drum support on drum assembly.

23. Install motor on motor end drum support, ensuring to

engage brake drive with brake shaft end.

24. Install three tie rods between drum supports and secure

with six bolts. Tighten bolts to 18 lb-ft (24 N•m).

NOTE:

If motor or control have been pre-coated with sealing

compound, remove compound from between motor case and
control mounting gear contact area. Failure to do so may cause
improper grounding of control.

Figure 9-177: Control Unit and Motor

25. Connect three control leads to terminals and secure with

nuts (Figure 9-178).

26. Secure control to motor with clamp.

27. Re-coat motor end of winch (including all leads and

terminals) with PlastiDip Coating or equivalent
waterproofing compound.

28. Install winch assembly and winch cable.

Winch Electric Thermal Switch/Brush
Assembly Replacement

Removal

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.

Remove three nuts and control leads from motor
(Figure 9-178).

Loosen clamp and remove control from motor
(Figure 9-179).

MOTOR, 12 VDC

SHOWN WITHOUT CONTROL

SPACER (2)

DRUM SUPPORT

BRAKE

DRUM

ASSEMBLY

DRIVER

MOTOR END

DRUM SUPPORT

MOTOR END

TIE ROD

GEAR TRAIN

ASSEMBLY

CONTROL

CLAMP

MOTOR

Content .. 151 152 153 154 ..