Content .. 251 252 253 254 ..

Hummer H1 (2002+). Manual - part 253

______________________________________________________________

Accessories 13-5

05745159

Inspection

Inspect drum for damage to splined end flanges and tube
(Figure 13-12). Replace winch if damaged.

Figure 13-12: 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 13-13).

Figure 13-13: Gear Carriers

Inspect brake assembly for damage (Figure 13-18).

Inspect motor, spline, mating surface, and terminals for
damage. Replace motor if damaged (Figure 13-14).

Figure 13-14: Motor and Control Unit

10. Inspect cover for damage. Replace if damaged.

11. Inspect control for damaged leads and damaged mounting

base. Replace control if damaged.

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

00-S13-007

COVER

LEAD

CONTROL

SPLINE

MOTOR

DRUM

SUPPORT

SPACER

CLAMP

13-6

Accessories

_______________________________________________________________

Assembly

Position 85 to 87 steel balls in groove of intermediate ring
gear and install intermediate ring gear in gear housing
(Figure 13-15).

Figure 13-15: 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 13-16).

Figure 13-16: 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 13-17).

Figure 13-17: 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

socket-head cap 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 13-17).

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

Figure 13-18: Thrust Washers and Brakes

O- RING

CLUTCH

LEVER

DETENT

BALL

SPRING

DETENT

SPACER

INTERMEDIATE

RING GEAR

RETAINING

RING

STEEL

BALLS

GEAR

HOUSING

SEAL

OUTPUT

GEAR

OUTPUT

RING GEAR

INTERMEDIATE

GEAR CARRIER

GASKET

INPUT

GEAR CARRIER

ASSEMBLY

GEAR

HOUSING

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

TOLERANCE

RING

ASSEMBLY

______________________________________________________________

Accessories 13-7

05745159

17. With drum horizontal, install brake into drum

(Figure 13-18).

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 13-19).

Figure 13-19: 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 13-20: Control Unit and Motor

25. Connect three control leads to terminals and secure with

nuts (Figure 13-21).

26. Secure control to motor with clamps (Figure 13-20).

27. Install winch assembly and winch cable.

Winch Electric Thermal Switch/Brush
Assembly Replacement

Removal

Remove winch and winch cable.

NOTE:

Tag leads for assembly.

Remove three nuts and control leads from motor
(Figure 13-21).

Loosen clamps and remove control from motor
(Figure 13-22).

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

00-S13-006

CONTROL

CLAMP

MOTOR

13-8

Accessories

_______________________________________________________________

Figure 13-21: Control Leads

Figure 13-22: Control Unit and Motor

Remove clamps from motor.

Place winch on end with motor end up (Figure 13-25).

Remove two bolt assemblies and rear cover from motor
housing.

NOTE:

Perform steps 7 through 11 only if replacing brush as-

sembly.

Remove electric thermal switch from two electric thermal
switch leads.

Remove motor housing from drum support and armature
assembly from brush assembly (Figure 13-24).

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 13-23: 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.

Install washer, insulator, and spacer on brush assembly
power stud (Figure 13-24).

Install brush assembly in motor housing with three screws
and nuts

Figure 13-24: 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

POWER

ASSEMBLY

STUD

Content .. 251 252 253 254 ..