Hummer H1 (2006+). Manual - part 205

5-60

Transmission/Transfer Case

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Figure 5-50:   Input Gear Snap Ring Removal

Figure 5-51:   Input Gear Retaining Ring Removal

Figure 5-52:   Input/Low Range Planetary Gear Disassembly Sequence

33. Remove and disassemble the differential as follows:

SNAP RING

INPUT GEAR

INPUT GEAR

LOW RANGE

PLANETARY

RETAINING

RING

LOW RANGE

PLANETARY

INPUT
GEAR

LOCK RING

FRONT

THRUST

WASHER

REAR

THRUST

WASHER

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 Transmission/Transfer Case  5-61

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a.

Scribe or paint a mark on the front and the rear cases for assembly reference (Figure  5-53).

b.

Remove the case bolts (Figure  5-54).

c.

Pry the front and the rear cases apart with two screwdrivers (Figure  5-55).

d.

Remove the planet gears and the thrust washers (Figure  5-56).

e.

Remove the sprocket and the mainshaft gears as an assembly (Figure  5-57).

34. Remove the output shaft front bearing seal with pry tool (Figure  5-58).

Figure 5-53:   Marking Differential Cases for Assembly Reference

Figure 5-54:   Differential Case Bolt Removal

Figure 5-55:   Separating Differential Cases

REAR CASE

FRONT CASE

ALIGNMENT SCRIBE

OR PAINT MARK

CASE BOLTS

FRONT CASE

REAR CASE

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5-62

Transmission/Transfer Case

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Figure 5-56:   Planet Gear Locations In Bottom Case

Figure 5-57:   Mainshaft and Sprocket Gear Removal

Figure 5-58:   Removing Front Output Shaft Seal

SPROCKET

GEAR

PLANET

GEARS (6)

FRONT

CASE

THRUST

WASHERS (12)

MAINSHAFT GEAR

SPROCKET GEAR

SHAFT

SEAL

FRONT CASE

PRY TOOL

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 Transmission/Transfer Case  5-63

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TRANSFER CASE CLEANING AND INSPECTION

Clean the transfer case components thoroughly with standard parts cleaning solvent. Remove all traces of sealer from the case and
retainer sealing surfaces.

Clean the oil pickup screen with solvent and dry it with compressed air. Also use compressed air to remove solvent residue from all
oil feed passages and channels.

Geartrain

The differential pinion gears and thrust washers are serviceable components and can be replaced if worn or damaged. The differen-
tial cases are also serviceable but must be replaced as a set if either case is damaged.

Inspect the mainshaft splines, gear teeth and bearing surfaces carefully for evidence of wear or damage. Replace the shaft if neces-
sary. Do not attempt to salvage it if damaged.

The range and mode forks are serviced as assemblies. Replace either part if damaged. However, the nylon pads in the forks can be
replaced if worn or cracked.

Inspect the transfer case snap rings closely. Do not attempt to salvage a distorted snap ring by straightening or reshaping it. Replace
any snap ring that is distorted or worn.

Inspect the low range planetary, input gear and thrust washer, retainer and snap ring. The low range planetary is serviced as an as-
sembly only. Replace it if the case or pinions are damaged.

During inspection, also make sure the seal surface of the input gear is in good condition. Minor nicks on this surface can be reduced
with crocus cloth. However, replace the gear if the seal surface is severely scored or worn.

Check condition of the low range annulus gear (Figure  5-59). Replace the front case and gear as an assembly if the gear is dam-
aged. The annulus gear is not serviced separately.

The speedometer tone wheel should be replaced if worn, cracked or spline teeth are worn.

Inspect the differential gears, thrust washers and case halves. Replace the mainshaft gear if the gear teeth or the brass ring on the
underside of the gear are damaged. Replace the differential as an assembly if the gears, case halves or the pins in the lower case
half are damaged.

Inspect the case halves, extension housing, and both retainers for cracks, porosity or damaged sealing surfaces. Inspect the shafts,
gears, chain and shift components for wear or damage.

Inspect all of the transfer case bearings for wear, roughness, pitting or galling. Replace worn or damaged bearings.

Figure 5-59:   Annulus Gear Location In Front Case

FRONT CASE

ANNULUS GEAR

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