Hummer H1 (2006+). Manual - part 211

5-84

Transmission/Transfer Case

_______________________________________________

Figure 5-103:   Oil Pump Assembly Installation

Figure 5-104:   Chip Magnet Installation

37. Apply 3/16 in. (5 mm) wide bead of Loctite 518, Permatex Ultra Black or Ultra Copper to the flange surface of the rear

retainer.

38. Align and install the rear retainer (Figure  5-108). Install and tighten the retainer bolts to 22-25 lb-ft (30-34 N•m).

39. Install the mainshaft bearing snap ring (Figure  5-108).

40. Apply 3/16 in. (5 mm) wide bead of Loctite 518, Permatex Ultra Black or Ultra Copper to the extension housing flange.

41. Align and install the extension housing on the rear retainer (Figure  5-109). Install and tighten the housing bolts to 20-25 lb-ft

(27-34 N•m).

42. Check the seal contact surface of the front yoke. Smooth surface with 320-400 grit, use emery if necessary. Then lubricate the

seal surface with Dexron III and install the yoke, new seal washer and a new yoke nut. Tighten the yoke nut to 130-200 lb-ft
(176-271 N•m). Use yoke tool J–8614-01 to hold the yoke while tightening the nut (Figure  5-110).

OIL PUMP

REAR 

OIL PICKUP

SCREEN

CASE 

PICKUP 

NOTCH

CASE

 TUBE

CHIP

MAGNET

FRONT

CASE

POCKET

10-1-08

_______________________________________________

 Transmission/Transfer Case  5-85

5745804

Figure 5-105:   Rear Case Installation

Figure 5-106:   Tone Wheel Speedometer Installation

REAR

CASE

DOWEL

OIL

PUMP

SNAP RING

TONE WHEEL

SNAP RING

MAINSHAFT

10-1-08

5-86

Transmission/Transfer Case

_______________________________________________

Figure 5-107:   Installing Mainshaft Bearing In Rear Retainer

Figure 5-108:   Rear Retainer and Mainshaft Bearing Snap Ring Installation

Figure 5-109:   Extension Housing Installation

TOOL

J–33832

BEARING

TOOL

HANDLE

J–8092

REAR

RETAINER

SNAP

RING

MAINSHAFT

BEARING

REAR

RETAINER

EXTENSION

HOUSING

10-1-08

_______________________________________________

 Transmission/Transfer Case  5-87

5745804

Figure 5-110:   Front Yoke Installation

43. Install the drain plug in the rear case. Tighten the plug to 15-25 lb-ft (20-33 N•m).

44. Apply Loctite PST to the threads of the indicator switches and the speed sensor.

45. Install the indicator switches. Tighten the switches to 15-25 lb-ft (20-33 N•m).

46. Install the speed sensor. Tighten the sensor to 30-35 lb-ft (41-47 N•m).

47. The transfer case can be filled before or after installation in the vehicle. Tighten the fill plug to 15-25 lb-ft (20-33 N•m) after

fill.

TRANSFER CASE TORQUE SPECIFICATIONS

Case bolts (all)
Detent plug
Drain/fill plugs
Exhaust bracket nuts
Extension housing bolts
Front retainer bolts
Front output shaft yoke nut
Indicator switches (both)
Oil cooler tube nuts
Range lever nut
Rear retainer bolts
Speed sensor
Transfer case mounting nuts

20-25 lb-ft (27-34 N•m)
12-18 lb-ft (16-24 N•m)
15-25 lb-ft (20-33 N•m)
18-22 lb-ft (24-30 N•m)
20-25 lb-ft (27-34 N•m)
12-18 lb-ft (16-24 N•m)
130-200 lb-ft (176-271 N•m)
15-25 lb-ft (20-34 N•m)
150-230 in.-lb (17-26 N•m)
20-25 lb-ft (27-34 N•m)
22-25 lb-ft (30-34 N•m)
30-35 lb-ft (41-47 N•m)
20-26 lb-ft (27-35 N•m)

YOKE

NUT

SEAL 

FRONT 

FRONT 

OUTPUT 

YOKE

OUTPUT SHAFT

WASHER

10-1-08