Hummer H1 (2006+). Manual - part 207

5-68

Transmission/Transfer Case

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Figure 5-69:   Extension Housing Bushing Replacement

Figure 5-70:   Extension Housing Seal Installation

TOOL

HANDLE

TOOL

J–33839

TOOL

HANDLE

TOOL

J–33839

NEW

BUSHING

INSTALLATION

REMOVAL

J–8092

J–8092

NEW SEAL

EXTENSION

HOUSING

SUITABLE SIZE

SEAL INSTALLER

J–33843 OR

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 Transmission/Transfer Case  5-69

5745804

Figure 5-71:   Rear Thrust Washer Installation

Figure 5-72:   Input Gear Installation

TRANSFER CASE ASSEMBLY

1.

Assemble the input gear and the low range planetary:

a.

Lubricate the gear, planetary and the thrust washers with Dexron III (Figure  5-71).

b.

Install the rear thrust washer in the planetary. Be sure the washer tabs are aligned in the planetary notches as shown 
(Figure 5-72)

NOTE: The thrust washers are the same size, and are interchangeable. Either washer can be used at the front or rear.

c.

Install the input gear in the planetary (Figure  5-73).

d.

Install the front thrust washer. Be sure the washer tabs are seated in planetary notches as shown (Figure  5-73).

e.

Install the lock ring (Figure  5-74) and the lock ring retainer (Figure  5-75).

2.

Lubricate the shift sector shaft and install the sector in the case (Figure  5-76).

3.

Install the input gear/planetary assembly in the front case (Figure  5-77). Use a wood hammer handle to tap the input gear shaft
through the bearing.

4.

Install the input gear snap ring (Figure  5-78).

5.

Install the front retainer as follows:

a.

Install a new seal in the retainer with tool J–33831 (Figure  5-79).

b.

Apply a 3/16 in. (5 mm) bead of Loctite 518, Permatex Ultra Black, or Ultra Copper to seal the surface of the retainer.

c.

Align the oil feed slot in the retainer with the feed hole in the front case, and install the retainer (Figure  5-80).

d.

Install and tighten the retainer bolts to 12-18 lb-ft (16-24 N•m).

LOWRANGE

PLANETARY

REAR THRUST

WASHER

LOW

RANGE

PLANETARY

INPUT
GEAR

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5-70

Transmission/Transfer Case

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Figure 5-73:   Front Thrust Washer Installation

Figure 5-74:   Lock Ring Installation

Figure 5-75:   Input Gear Snap Ring Installation

6.

Assemble the low range fork and hub. Replace the pads on the fork if worn or damaged (Figure  5-81).

FRONT

THRUST

WASHER

LOW RANGE

PLANETARY

INPUT GEAR

LOCK RING

LOCK

RING

RETAINER

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 Transmission/Transfer Case  5-71

5745804

7.

Install the low range fork and hub. Be sure the hub is seated in the planetary and that the fork pin is seated in the shift sector
lower slot (Figure  5-82).

Figure 5-76:   Shift Sector Installation

Figure 5-77:   Input Gear/Low range Planetary Installation

8.

Assemble the differential as follows:

a.

Lubricate the differential cases, gears and thrust washers with Dexron III.

b.

Install the mainshaft gear in the front case (Figure  5-83).

c.

Install the sprocket gear.

d.

Install a thrust washer on each of the front case pinion pins.

e.

Install the long and the short pinions in sets (Figure  5-84).

f.

Install the thrust washer at the top of each pinion.

g.

Align and install the rear case on the front case. Be sure the case alignment paint or scribe marks are matched as shown
(Figure 5-85).

h.

Install and tighten the differential case bolts evenly.

FRONT

CASE

SHIFT

SECTOR

INPUT GEAR

BEARING

INPUT GEAR/

PLANETARY

ASSEMBLY

10-1-08