Hummer H1 (2002+). Manual - part 156

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 Axles, Suspension, and Frame  9-85

®

05745159

17. With drum horizontal, install brake into drum

(Figure 9-201).

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 9-202).

Figure 9-202:    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).

Figure 9-203:   Control Unit and Motor

25. Connect three control leads to terminals and secure with

nuts (Figure 9-204).

26. Secure control to motor with clamps (Figure 9-203).

27. Install winch assembly and winch cable.

Winch Electric Thermal Switch/Brush 
Assembly Replacement

Removal

1.

Remove winch and winch cable.

NOTE: 

Tag leads for assembly.

2.

Remove three nuts and control leads from motor
(Figure 9-204).

3.

Loosen clamps and remove control from motor
(Figure 9-205).

MOTOR, 12 VDC

SHOWN WITHOUT CONTROL

SPACER (2)

DRUM SUPPORT

BRAKE 

BRAKE 

DRUM

ASSEMBLY

DRIVER

 MOTOR END

DRUM SUPPORT

 MOTOR END

TIE ROD

GEAR TRAIN

ASSEMBLY

00-S13-006

CONTROL

CLAMP

MOTOR

9-86

Axles, Suspension, and Frame

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®

Figure 9-204:   Control Leads

Figure 9-205:   Control Unit and Motor

4.

Remove clamps from motor.

5.

Place winch on end with motor end up  (Figure 9-208).

6.

Remove two bolt assemblies and rear cover from motor
housing.

NOTE: 

Perform steps 7 through 11 only if replacing brush as-

sembly.

7.

Remove electric thermal switch from two electric thermal
switch leads.

8.

Remove motor housing from drum support and armature
assembly from brush assembly (Figure 9-207).

9.

Remove nut, lockwasher, washer, and insulator securing
brush assembly power stud to motor housing. Discard
lockwasher.

10. Remove three nuts, screws, and brush assembly from

motor housing.

11. Remove spacer, insulator, and washer from brush

assembly power stud.

Figure 9-206:    Motor and Gasket 

Installation 

NOTE: 

Do not apply coating to any electrical contacts of the

armature assembly. Perform steps 1 through 5 only if replacing
brush assembly.

1.

Install washer, insulator, and spacer on brush assembly 
power stud (Figure 9-207).

2.

Install brush assembly in motor housing with three screws
and nuts

.

Figure 9-207:    Brush Assembly and Armature 

Assembly

00-S13-005

CLAMP

DRUM SUPPORT

NUT

MOTOR

CONTROL

LEAD

TERMINAL

CONTROL

00-S13-009

MOTOR

CLAMP

SPACER

DRUM SUPPORT

CONTROL

REAR COVER

SPACER

ELECTRIC THERMAL

SWITCH

ELECTRIC THERMAL

SWITCH LEADS

MOTOR

HOUSING

BOLT 

ASSEMBLY 

SPACER

MOTOR

HOUSING

ARMATURE

ASSEMBLY

BRUSH 

BRUSH 

POWER 

ASSEMBLY

ASSEMBLY

STUD

________________________________________

 Axles, Suspension, and Frame  9-87

®

05745159

3.

Secure brush assembly power stud to motor housing with
insulator, washer, lockwasher, and nut.

4.

Coat armature shaft with lubricant and install in brush
assembly.

5.

Coat head of electric thermal switch with lubricant and
connect to two electric thermal switch leads
(Figure 9-206).

6.

Position spacer in drum support, and install rear cover on
motor housing.

7.

Install motor on drum support ensuring to engage motor
shaft into brake drum.

8.

Secure motor to motor end drum support with two bolt
assemblies. Tighten hex-head bolt to 60-70 lb-in. (7-8
N•m)  (Figure 9-208).

Figure 9-208:   Control Unit and Motor 

9.

Install clamps on motor.

10. Install control on motor.

11. Connect three control leads to terminals and secure with

nuts (Figure 9-204).

12. Secure control to motor with clamps.

13. Install winch assembly and winch cable.

Winch Roller Fairlead (Option) 
Replacement

The winch roller fairlead provides greater functional versatil-
ity. The winch cable can be routed at much sharper angles
since the fairlead rollers will keep it from binding on the
bumper edges.

Removal

WARNING:  To avoid injury or damage, support winch
during removal.

1.

Remove circlips on one vertical and one horizontal roller.

2.

Remove one vertical and one horizontal roller.

3.

Remove washers, bolts, and the roller fairlead from the
front bumper  (Figure 9-209). 

Figure 9-209:   Winch Fairlead

Installation

1.

Place the winch cable and hook assembly through the 
roller fairlead and install the fairlead on the front bumper 
with washers and bolts. Tighten bolts to 60 lb-ft (81 N•m)  
(Figure 9-209). 

2.

Install the horizontal and vertical rollers and circlips.

00-S13-008

MOTOR

MOTOR END

DRUM SUPPORT

CLAMP

CONTROL

FAIRLEAD

WASHER

FRONT 

BUMPER

 

9-88

Axles, Suspension, and Frame

 

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®

 

ESSENTIAL TOOLS

 

Procure from Kent-Moore.

TOOL

DESCRIPTION

 

J–8092

Universal Driver Handle

J–24319-B

Steering Linkage and Tie Rod Puller

J–8001

Dial Indicator

J–29162

Rear Retainer Seal Installer

J–44905

Input Seal Installer

J–8614-O1

Yoke Holding Tool (includes J–8614-5 bolt kit)

J–42545

Clampnut Socket

J–44906

Spindle Seal Installer (not shown)

J–38869

Seal Installer (not shown)

J–35910

Axle Boot Crimping Tool (not shown)

J–42546

1/4 in. Drive Torque Wrench (Preset) (not shown)

J–42547

3/8 in. Drive Torque Wrench (Preset) (not shown)

J–42591

Steering Cover Seal Installer (not shown)

J–29162

J–44905

J–24319-B

J–8001

J–42545

J–8092

J–8614-O1

 

3-1-01