Hummer H1 (2002+). Manual - part 175

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 Body  10-71

®

05745159

SOFT TOP SUPPORT ASSEMBLY 

Removal

1.

Remove soft top.

2.

Remove interior grab handles.

3.

Remove vinyl wrap and padding from roll cage assembly.

4.

Remove inner door seals.

5.

Drill rivets on front corner filler plates located at top front
of front door openings.

6.

Remove H rails, B- and C-pillar covers.

7.

Remove hardware and door striker from B-pillar.

8.

Remove fasteners securing the windshield frame to
support structure, and rear supports to the body.

9.

Using an overhead hoist, remove the support structure as a
complete assembly.

10. Repair or replace individual pieces as necessary, leaving

hardware loose, so the new pieces can be adjusted to the
structure once the unit is installed.

Installation

1.

Apply sealer to rear support where body contact is made.

2.

Lower structure assembly onto vehicle. 

3.

Install hardware and strikers in B-pillar and front and rear
supports.

4.

Install H rail, B- and C-pillar covers. Use body sealer
where removed.

5.

Apply sealer to filler plates and rivet to body using
existing holes.

6.

Tighten hardware on assembly.

7.

Install new inner door seals.

8.

Install padding and vinyl wrap on roll cage assembly. 

9.

Install interior grab handles.

10. Install soft top and leak check.

Figure 10-139:   Support Structure Assembly

C PILLAR

B PILLAR

B BAR

B PILLAR

C PILLAR

C PILLAR
REAR SUPPORT

C PILLAR
REAR SUPPORT

 CENTER

10-72

Body

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®

TAILGATE 

Tailgate Chain and Latch Brackets 
Replacement

Removal 

Remove four locknuts, eight washers, four bolts, chain bracket,
and latch bracket from body (Figure 10-140).

Installation 

Secure chain bracket and latch bracket to body with four bolts,
eight washers, and four locknuts. Tighten bolts to 15 lb-ft (20
N•m) (Figure 10-140).

Figure 10-140:   Tailgate Bracket Installation

Cargo Tiedown Replacement

NOTE: 

Cargo tiedown replacement is basically the same for

all tiedowns.

Removal 

Remove locknut, washer, screw, and cargo tiedown from cargo
floor (Figure 10-141).

Installation 

Install cargo tiedown on cargo floor with screw, washer, and
locknut. Tighten locknut to 65 lb-ft (88 N•m)  (Figure 10-141).

Figure 10-141:   Cargo Tiedown Replacement

Tailgate and Seals Replacement

Removal 

1.

Remove six locknuts, washers, and bolts securing tailgate 
to body  (Figure 10-142).

2.

Disconnect two chains from tailgate and remove tailgate
and shims from body.

NOTE: 

Perform step 3 for two- and four-door models. Per-

form step 4 and 5 for station wagon and open body models.

3.

Remove two vertical seals from tailgate. Discard seals.

4.

Remove two vertical and horizontal seals from body and
four vertical seals and one horizontal seal from tailgate.
Remove two corner seals (station wagon model only).
Discard seals  (Figure 10-143).

5.

Remove two corner seals from tailgate (station wagon
model only). 

6.

Remove two grommets from tailgate.

7.

Clean adhesive from tailgate and body.

Figure 10-142:   Tailgate and Seals Replacement

BODY

CHAIN BRACKET

LATCH BRACKET

CARGO FLOOR

SCREW

CARGO
TIEDOWN

VERTICAL SEAL

BODY

CHAIN

SHIM

TAILGATE

_____________________________________________________________________

 Body  10-73

®

05745159

Installation 

1.

Install two grommets on tailgate  (Figure 10-143).

NOTE: 

Perform steps 2 through 4 for station wagon and open

body models. Perform step 5 for two- and four-door models.

2.

Remove paper backing and install four vertical seals and
one horizontal seal on tailgate. Ensure upper vertical seals
overlap lower seals.

3.

Remove paper backing from two horizontal and vertical
seals and install on body.

4.

Remove paper backing from two corner seals and install
on tailgate (station wagon model only).

5.

Remove paper backing from two vertical seals and install
seals on tailgate  (Figure 10-142).

6.

Secure tailgate to body with six bolts, washers, and
locknuts. Shim hinges as needed to align tailgate with
body. When aligned, tighten bolts 26 lb-ft (35 N•m).

7.

Attach the two tailgate chains bracketed to the body to the
tailgate.

Figure 10-143:   Tailgate Mounting Bracketry 

and Seal Location

Tailgate Chain Replacement

Removal 

1.

Lower tailgate.

2.

Open chain cap link and disconnect chain from bracket
(Figure 10-144).

3.

Unhook chain from chain bracket.

Installation 

1.

Hook chain to chain bracket (Figure 10-144).

2.

Connect chain to bracket.

3.

Raise tailgate.

Figure 10-144:   Tailgate Chain Replacement

TAILGATE HINGE REPLACEMENT

NOTE: 

To facilitate alignment when replacing hinges, place a

small strip of masking tape along each side and bottom of
hinge before removal.

Removal

Remove tailgate by removing six locknuts, washers, and bolts
from the tailgate while still closed. Note number of shims un-
der each hinge and set them aside. Remove tailgate by releas-
ing tailgate chains (Figure 10-145).

Figure 10-145:   Tailgate Hinge Replacement

Disassembly

1.

Place tailgate on padded work surface and remove hinge 
retainer rivets. Remove hinge and clean any debris from 
rivet holes.

2.

Clean tailgate and apply a light coat of seam sealant to
hinge mounting area.

HORIZONTAL 

VERTICAL

TAILGATE

CORNER SEAL

GROMMET

VERTICAL 

VERTICAL

HORIZONTAL SEAL

BODY

SEAL 

(LOWER)

 SEAL (UPPER)

SEAL

 SEAL

BRACKET

CHAIN BRACKET

CHAIN

CAP LINK

SHIM

LOWER

UPPER 

LOWER 

 HINGE

RETAINER

 RIVET

RETAINER

 RIVET

UPPER

HINGE

CHAIN

10-74

Body

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®

Assembly

1.

Using three 0.187 in. x 0.626 in. rivets, fasten hinge to 
lower set of holes on tailgate. 

2.

Fasten hinge to upper set of holes on tailgate with three
0.187 in. x 0.563 in. rivets.

Installation

1.

Position tailgate on bed and secure with tailgate chains. 
Loosely install bolts, washers, and locknuts into hinges. 
Insert proper amount of shims under each hinge.

2.

Slightly tighten bolts, but not tight enough to restrict
movement into alignment with tape marks.

3.

Align hinges and tailgate into proper position and torque
bolts to 26 lb-ft (35 N•m). Remove any excess sealant
from hinges and body.

4.

Refinish hinges and fasteners as required.

REAR VERTICAL DOOR REPLACEMENT

Removal

1.

Remove seven screws securing hinge to door.

2.

Slowly pull door away from the hinge to expose interior
lock harness connections.

3.

Disconnect interior door lock harness from contacts on
hinge, and tape to door to prevent loss.

Figure 10-146:   Rear Vertical Door Replacement

Installation

1.

Position door close to hinge to allow the interior door lock 
harness to be connected to the contacts on the hinge.

2.

Secure hinge to door frame with seven screws (Figure 10-146). 

3.

Verify operation of door locks and door latch .

4.

If alignment is necessary, loosen the seven screws on the
interior side of the door hinge. The slots in the hinge will
allow up and down adjustment.

5.

Tighten the seven screws in the hinge.

Window Replacement

Removal

Remove eleven screws, window retainer bracket, and window
from rear vertical door (Figure 10-147). 

Figure 10-147:   Window Replacement

Installation

Secure window to rear vertical door with window retainer
bracket and eleven screws (Figure 10-147). 

REAR

VERTICAL

DOOR

DOOR

FRAME

WINDOW

WINDOW

REAR

VERTICAL

DOOR

 RETAINER

BRACKET