Hummer H2. Manual - part 2191

REPAIR INSTRUCTIONS 

ALUMINUM WHEEL POROSITY REPAIR 

1. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation .  

2. Inflate the tire to the manufactures specified pressure as stated on the tire.  

3. Submerge the tire/wheel into a water bath in order to locate the leak.  

4. Inscribe a mark on the wheel in order to indicate the leak areas.  

5. Inscribe a mark on the tire at the valve stem in order to Indicate the orientation of the tire to the wheel.  

6. Remove the tire from the wheel. Refer to Tire Mounting and Dismounting . 

7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area.  

8. Use general purpose cleaner such as 3M(R), P/N 08984 or equivalent, to clean the leak area.  

9. Apply 3 mm (0.12 in) thick layer of adhesive/sealant, GM P/N 12378478 (Canadian P/N 88900041) or 

equivalent, to the leak area.  

10. Allow for the adhesive/sealant to dry.  

11. Align the inscribed mark on the tire with the valve stem on the wheel.  

12. Install the tire to the wheel. Refer to Tire Mounting and Dismounting .  

13. Inflate the tire to the manufactures specified pressure as stated on the tire.  

14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed.  

surface.  

Does the vehicle still lead/pull?

Go to Step 6

Go to Step 7

6

1. Cross-switch the right front tire/wheel 

assembly with the right rear tire/wheel 
assembly. Refer to Tire and Wheel 
Removal and Installation .  

2. Road test the vehicle on a smooth level 

surface.  

Does the vehicle still lead/pull?

Go to Measuring 

Wheel Alignment in 

Wheel Alignment

Go to Step 8

7

Replace the left rear tire. Refer to Tire Mounting 
and Dismounting . 
Is the repair complete?

Go to Step 9

-

8

Replace the right rear tire. Refer to Tire 
Mounting and Dismounting . 
Is the repair complete?

Go to Step 9

-

9

Verify proper vehicle operation. 
Does the original condition still exist?

Go to Step 1

System OK

IMPORTANT: Do not damage the exterior surface of the wheel.

 

2004 Hummer H2 

2004 SUSPENSION Tires and Wheels - Hummer H2

  

15. Balance the tire and wheel. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle in Vibration 

Diagnosis and Correction.  

16. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation .  

17. Lower the vehicle.  

ALUMINUM WHEEL REFINISHING 

Aluminum Wheel Refinishing Guidelines 

Evaluating Damage 

Aluminum Wheel Refinishing General Recommendations/Options 

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Painted aluminum wheels use a primer, color coat, and clearcoat procedure. If the paint is damaged, 
refinishing is possible. As with polished wheels, all original coatings must be removed first. Media 
blasting is recommended. (See option number 1).  

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If the clearcoat is damaged, it is possible to refinish with clearcoat only, however, the required refinishing 
process cannot be performed in the dealer environment. Refer to Refinishers Responsibility (Repair 
option #2).  

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Re-plating of chrome-plated aluminum wheels is not recommended.  

Repair Option Number 1 

Material Required/Information Resources 

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The Paint Manufactures Color Book  

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Refer to the latest GM Approved Refinish Materials Booklet (GM 4901 MD-2005) for specific products 
for aluminum refinishing.  

CAUTION: To avoid personal injury when exposed to plastic media blast, hand and/or 

lathe sanding dust, primer, color coat, and clearcoat, you must work in a 
properly ventilated area, wearing an approved respirator, eye protection, 
earplugs and protective gloves and clothing.

IMPORTANT:

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Inspect the wheel for corrosion, scrapes, gouges, etc. Damage MUST NOT 
be deeper than what can be sanded or polished off.  

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Inspect the wheel for cracks. If cracks are found, discard the wheel.  

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ALL wheels with bent rim flanges must not be repaired or refinished.  

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The re-machining and the re-clear coating of aluminum wheels is not 
recommended in the dealer environment due to concerns of repair 
durability.  

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Do not use any re-machining process that removes aluminum. This could 
affect the dimensions and function of the wheel.  

 

2004 Hummer H2 

2004 SUSPENSION Tires and Wheels - Hummer H2

  

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To access the booklet, go to www.gmgoodwrench.com. Click on GM Collision Parts. Click on GM 
Technical Repair Information, select Paint Shop.  

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A Color Compatibility chart is also at this site defining what colors are used on what models. 

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Refer to specific Paint Manufactures for refinish procedures and process pertaining to "Aluminum 
Refinishing". 

The procedure requires the wheel surface to be plastic media blasted to remove old paint or clearcoat. 

General Color Selection 

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If the wheels being painted were previously clearcoated aluminum, and a painted aluminum look is 
desired, using Corsican Silver WAEQ9283 for a fine "aluminum-like" look, or Sparkle Silver WA9967 
for a very bright look. Body color is another option to the customer that may also be used.  

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Some specific colors may be recommended on certain models (currently SSR and GTO).  

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If painting wheels that were previously clearcoated aluminum, it is recommended that all four wheels and 
their center caps be refinished to maintain color uniformity.  

General Refinishing Procedures-Removal 

1. Remove the wheels from the vehicle. The tires may remain mounted on the wheels.  

2. Remove the balance weights and mark their locations on the tire.  

3. Remove excess grease, etc. from the wheels with wax and grease remover.  

4. Have the wheels plastic media blasted to remove the clearcoat. 

5. Clean and mask and paint the wheels.  

General Refinishing Procedures-Installation 

1. Unmask the wheels.  

2. Clean all wheel mounting surface of any corrosion, overspray, or dirt. 

3. Install NEW coated balance weights at marked locations. 

IMPORTANT: Chemical strippers are not recommended.

IMPORTANT: MASK OFF ALL MOUNTING SURFACES, whenever a wheel is refinished. 

The mounting surface and the wheel nut contact surfaces must not be 
painted or clearcoated. Coating these surfaces could affect the wheel nut 
torque.

IMPORTANT: When re-balancing a tire on an aluminum wheel, coated balance weights 

must be used in order to reduce the chance of future cosmetic damage.

 

2004 Hummer H2 

2004 SUSPENSION Tires and Wheels - Hummer H2

  

4. Install wheels on vehicle.  

Repair Option Number 2. Outside Companies 

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Some outside companies are offering wheel refinishing services. One such company, Transwheel 
Corporation (800-892-3733), provides this service with GM guidelines. Other companies may also exist.  

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Any process that re-machines or otherwise remanufactures the wheel should not be used.  

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The wheel ID must be recorded and follow the wheel throughout the process to assure that the same 
wheel is returned. The refinisher must permanently ID stamp the wheel and warrant the 
painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, 
whichever is longer.  

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Paint and/or clearcoat must not be present on the following surfaces: the nut chamfers, the wheel 
mounting surfaces and the wheel pilot hole.  

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A refinishers responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any 
cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. A 
plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined 
surface and the wheel window is allowed. Material removal, though, must be kept to a minimum.  

TIRE AND WHEEL REMOVAL AND INSTALLATION 

Tools Required 

J 39544-KIT Complete Torque Socket Set 

IMPORTANT: Use a torque stick on an impact wrench, or a torque wrench to 

consistently and uniformly fasten the wheel to the specified torque for the 
vehicle. The star pattern must be followed.

CAUTION: If penetrating oil gets on the vertical surfaces between the wheel and the 

rotor or drum it could cause the wheel to work loose as the vehicle is 
driven, resulting in loss of control and an injury accident.

NOTE:

Never use heat to loosen a tight wheel. It can shorten the life of the wheel, 
studs, or hub and bearing assemblies. Wheel nuts must be tightened in 
sequence and to the specified torque to avoid bending the wheel or rotor.

NOTE:

Improperly tightened wheel nuts can lead to brake pulsation and rotor damage. 
In order to avoid expensive brake repairs, evenly tighten the wheel nuts to the 
proper torque specification.

IMPORTANT: Removing wheels can be difficult because of foreign material or a tight fit 

between the wheel center hole and the hub or rotor. Excessive force, such as 
hammering on the wheel or tire, can cause damage. Slightly tapping the tire 
side wall with a rubber mallet is acceptable.

 

2004 Hummer H2 

2004 SUSPENSION Tires and Wheels - Hummer H2