Hummer H1 (2006+). Manual - part 257

9-6 Axles, Suspension and Frame

___________________________________________

Cover Service

Removal

1.

Remove the drain plug from the axle assembly and drain the axle assembly (Figure  9-4).

2.

Remove the twelve bolts and cover from the axle assembly.

Figure 9-4:   Axle Assembly Cover Service

Cleaning and Inspection 

NOTE: Clean all the components, examine for wear or damage, and replace if necessary.

1.

Clean the axle assembly cover, bolts, and the axle assembly with solvent (Figure  9-4).

2.

Inspect the axle assembly cover for cracks, wear or breaks.

Installation

1.

Apply RTV sealant to the cover sealing surface and secure the cover to the axle assembly with the twelve bolts. Tighten the 
bolts to 16 lb-ft. (22 N•m).

2.

Thread the drain plug into the axle assembly and tighten to 13-18 lb-ft. (18-25 N•m) (Figure  9-4).

3.

Fill the axle assembly to the proper oil level (Refer to section 1).

Output Shaft Seal Replacement

Removal

1.

Remove the brake caliper and the yoke from the caliper adapter (disconnect the park brake cable from the rear calipers) and 
support the caliper to the side being careful not to kink the brake line.

2.

Disconnect the halfshaft at the axle flange and swing it off to the side.

3.

Remove the brake rotor.

4.

Remove the axle output flange retaining nut and the flange.

5.

Support the axle assembly, disconnect and move the axle assembly support bracket over to gain access to the output seal. 

6.

Remove the output shaft seal from the axle (Figure  9-5).

AXLE COVER

AXLE ASSEMBLY

DRAINPLUG

__________________________________________

 Axles, Suspension and Frame  9-7

Figure 9-5:   Axle Output Shaft Seal Replacement

Installation

1.

Using seal installer J–38869, install the output shaft seal in the axle assembly (Figure  9-5).

2.

Install the axle assembly support bracket.

3.

Install the axle output shaft flange and the nut using Loctite 242 (or equivalent) and torque to 166-196 lb-ft. (224-265 N.m).

4.

Install the brake rotor and the halfshaft. Use the bolts with pre applied Loctite or the original bolts with Loctite 272 (or
equivalent), cam-lock washers and torque to 57 lb-ft. (77 N.m).

5.

Install the brake caliper and the yoke using Loctite 272 (or equivalent) (connect the park brake cable on the rear calipers) and
torque to 40 lb ft. (54 N.m).

Pinion Seal Replacement

NOTE:  Removal and installation procedures for pinion seals are basically the same for front and rear axle assemblies. This proce-
dure covers the rear axle assembly pinion seal.

Removal

1.

Remove the six bolts, cam-lock washers, and the halfshaft from each output flange rotor.

2.

Remove the four bolts, two straps, and the rear propeller shaft. from the pinion yoke (Figure  9-6).

3.

Using a lb-in. torque wrench, measure the torque required to rotate the pinion and record the measurement.

4.

Count and record the number of exposed threads on the end of the pinion and mark the locknut and the pinion for assembly.

5.

Remove the locknut and the pinion yoke from the pinion.

6.

Remove the pinion seal from the pinion.

Figure 9-6:   Pinion Seal Replacement

AXLE SHAFT 

OUTPUT SHAFT SEAL

AXLE

AND SEAL 

INSTALLER

ASSEMBLY

J–38869

STRAP

PINION YOKE

PINION SEAL

PINION

 REAR PROPELLER SHAFT

SEAL DRIVER

J-38869

9-8 Axles, Suspension and Frame

___________________________________________

Installation

1.

Using a yoke seal installer J–38869, install the pinion seal on the pinion (Figure  9-6).

2.

Secure the pinion yoke to the pinion with the locknut.

3.

Tighten the locknut to the original position.

4.

Tighten the locknut in small increments, until the torque required to rotate the pinion exceeds the original measurement by 2
lb-in (0.2 N•m).

5.

Secure the rear propeller shaft. to the pinion yoke with the four bolts and the two straps. Tighten the bolts to 27 lb-ft. (37 N•m).

6.

Apply Loctite 272 to the halfshaft. mounting bolts.

7.

Secure the halfshaft to each output flange and the rotor with the twelve cam-lock washers and the six bolts. Tighten to 57 lb-ft.
(77 N•m).

Front Axle Assembly Replacement

Removal

CAUTION: Due to a torque bias ratio change, axle assemblies from previous model year vehicles must not be mixed with the cur-
rent assemblies.

1.

Remove the brake callipers and rotors (Refer to section 7).

2.

Remove the drain plug from the axle assembly. Allow the oil to drain and reinstall the drain plug.

3.

Remove the four bolts and the front propeller shaft from the pinion yoke.

WARNING:  Axle assembly must be supported during removal and installation. Failure to do this may cause per-
sonal injury or damage to equipment.

NOTE: If the axle assembly is being reused and not replaced it is NOT necessary to remove the output flanges or the caliper sup-
port bracket assemblies

4.

Remove the two output flanges and the two washer seals on the axle assembly.

5.

Support the axle assembly.

6.

Remove the two bolts and washers securing the axle assembly to the upper mounting bracket.

7.

Remove the two bolts and nuts from the caliper support bracket assemblies.

8.

Lower the axle assembly slightly and disconnect the vent line from the axle assembly.

9.

Remove the axle assembly.

10. Remove the eight bolts and the two brake caliper support bracket assemblies from the axle assembly.

__________________________________________

 Axles, Suspension and Frame  9-9

Figure 9-7:   Front Axle Location

Front Axle Installation 

1.

Apply Loctite 272 (or equivalent) thread-locking compound to the axle assembly tapped holes. Secure the two brake caliper 
adapters to the axle assembly with the eight bolts. Tighten the bolts to 125-150 lb-ft. (169-203 N•m) (Figure  9-8).

2.

Raise the axle assembly into place and connect the vent line.

NOTE: Positioning of the front axle is important, refer to front axle location (Figure  9-7).

3.

Apply Loctite 272 (or equivalent) thread-locking compound to the tapped holes of the upper mounting point. Install the two
washers, bolts and the axle assembly to the mounting bracket and torque to 125-150 lb-ft. (169-203 N•m).

4.

Install the lower mounting bolts, nuts and washers and torque to 125-150 lb-ft. (169-203 N•m).

5.

Secure the two output flanges and the two washer seals to the axle assembly with the two locknuts. Tighten the locknuts to
165-195 lb-ft. (224-264 N•m).

6.

Install the propeller shaft at the transfer case (Figure  9-7).

7.

Secure the propeller shaft to the pinion yoke with the four bolts and the two straps. Tighten the bolts to 12 lb-ft. (16 N•m)
(Figure  9-7).

8.

Install the service brake rotors (Refer to section 7).

9.

Fill the axle assembly to the proper oil level (Refer to section 1).

6.24''

(6 15/64'')

6.44''

(6 7/16'')