Hummer H2. Manual - part 2659

TRANSFER CASE CLUNK IN 4LO LOCK 

Transfer Case Clunk in 4LO Lock 

z

Loose or faulty pinion gears 

Refer to Cleaning and Inspection . 

2. Replace the planetary differential assembly if it is faulty. Refer to 

Transfer Case Disassemble and Transfer Case Assemble .  

Worn or missing rear output 
shaft thrust washers

1. Inspect to ensure the thrust washers are installed.  

2. Inspect the thrust washers and mating surface for excessive wear.  

3. Replace the worn or missing thrust washer. Refer to Transfer Case 

Disassemble and Transfer Case Assemble .  

Worn or damaged rear sun 
gear

1. Inspect the sun gear external gear teeth for excessive wear.  

2. Inspect the sun gear to rear output shaft for excessive looseness.  

3. Replace the sun gear or rear output shaft if it is worn. Refer to 

Transfer Case Disassemble and Transfer Case Assemble .  

Rear output shaft bearing 
outer retaining ring

1. Inspect for the following conditions: 

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Properly installed rear output shaft bearing retaining ring  

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Excessive wear or damage to the retaining ring groove in the 
rear case half 

Refer to Cleaning and Inspection . 

2. Repair or replace the following components if found faulty: 

1. Replace the rear output shaft bearing outer retaining ring.  

2. Replace the rear case half if the retaining ring groove is faulty. 

Refer to Transfer Case Disassemble and Transfer Case 
Assemble . 

Lockup shift assembly hub

1. Inspect the lockup shift assembly hub for the following conditions: 

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The hub internal teeth to inner lockup hub for excessive 
looseness caused by wear  

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The hub engagement teeth for wear 

Refer to Cleaning and Inspection . 

2. Replace the lockup shift assembly if it is faulty. Refer to Transfer 

Case Disassemble and Transfer Case Assemble .  

Cause

Correction

 

2004 Hummer H2 

2004 DRIVELINE/AXLE Transfer Case - BW 4484 - Hummer H2

  

TRANSFER CASE CLUNK DURING ACCELERATION AND DECELERATION 

Transfer Case Clunk during Acceleration and Deceleration 

DEFINITION: During acceleration or deceleration, a clunk is heard or felt in the transfer case while in 
4LO Lock range only. 
Review the Symptoms - Transfer Case and perform the necessary inspections.
High/low planetary 
carrier assembly

1. Inspect for the following conditions: 

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Excessively worn planetary gears  

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The planetary gears loose in the planetary carrier  

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The input gear for missing thrust washers or excessive thrust end play 
in the carrier  

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Excessively worn range sleeve engagement teeth on the carrier 

Refer to Cleaning and Inspection . 

2. Replace the high/low planetary if any of the above conditions are found. 

Refer to Transfer Case Disassemble and Transfer Case Assemble .  

Annulus gear

1. Inspect the annulus gear to front case fit for excessive looseness.  

2. Inspect the front case for wear caused by excessive looseness.  

3. Replace the front case half if it is worn.  

Range sleeve

1. Inspect the range sleeve engagement teeth for excessive wear.  

2. Inspect the range sleeve to mainshaft splines for excessive wear.  

3. Replace the range sleeve if it is faulty. Refer to Transfer Case 

Disassemble and Transfer Case Assemble .  

Cause

Correction

DEFINITION: During acceleration or deceleration, a clunk is heard or felt in the transfer case while in 
the 4HI mode. 
Review the Symptoms - Transfer Case and perform the necessary inspections.
Incorrect fluid level or incorrect 
fluid

1. Inspect the transfer case for the correct fluid level. Refer to 

Transfer Case Fluid Replacement .  

2. Inspect the transfer case for the correct type of fluid.  

3. Flush the transfer case and fill with the correct fluid, if required. 

Refer to Capacities - Approximate Fluid .  

Excessive clearance between the 
slip yoke and the rear output 
shaft

1. Inspect for the following conditions: 

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Worn slip yoke splines  

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Worn rear output shaft splines  

2. Repair or replace the following components, if faulty. 

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Replace the slip yoke, if required. Refer to Propeller 
Shaft Replacement - Rear in Propeller Shaft.  

 

2004 Hummer H2 

2004 DRIVELINE/AXLE Transfer Case - BW 4484 - Hummer H2

  

z

Replace the rear output shaft, if required. Refer to 
Transfer Case Disassemble and Transfer Case 
Assemble .  

Excessive clearance between the 
slip yoke and the rear bushing

1. Inspect for the following conditions: 

z

Worn rear bushing  

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Worn slip yoke bushing journal  

2. Repair or replace the following components, if faulty. 

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Replace the slip yoke, if required. Refer to Propeller 
Shaft Replacement - Rear in Propeller Shaft.  

z

Replace the rear case half if the rear bushing is worn. 
Refer to Transfer Case Disassemble and Transfer Case 
Assemble .  

Worn high speed teeth on the 
range sleeve

1. Inspect for the following conditions: 

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Worn high speed teeth on the range sleeve  

z

Worn or missing input gear thrust washers 

Refer to Cleaning and Inspection . 

2. Repair or replace the following components, if faulty. 

z

Replace the range sleeve if it is worn. Refer to Transfer 
Case Disassemble and Transfer Case Assemble .  

z

Replace the thrust washers, as required. Refer to 
Transfer Case Disassemble and Transfer Case 
Assemble .  

Worn or faulty planetary 
differential

1. Inspect the planetary differential for the following conditions: 

z

Loose planetary differential splines to the mainshaft 
splines  

z

Loose or faulty pinion gears 

Refer to Cleaning and Inspection . 

2. Replace the planetary differential assembly if it is faulty. Refer 

to Transfer Case Disassemble and Transfer Case Assemble . 

Worn or missing rear output shaft 
thrust washers

1. Inspect to ensure the thrust washers are installed.  

2. Inspect the thrust washers and mating surface for excessive 

wear.  

3. Replace the worn or missing thrust washer. Refer to Transfer 

Case Disassemble and Transfer Case Assemble .  

Worn or damaged rear sun gear

1. Inspect the sun gear external gear teeth for excessive wear.  

2. Inspect the sun gear to rear output shaft for excessive looseness. 

 

2004 Hummer H2 

2004 DRIVELINE/AXLE Transfer Case - BW 4484 - Hummer H2

  

TRANSFER CASE SHUDDER OR BINDING 

Transfer Case Shudder or Binding 

3. Replace the sun gear or rear output shaft if it is worn. Refer to 

Transfer Case Disassemble and Transfer Case Assemble .  

Worn or damaged front sun gear

1. Inspect the sun gear external gear teeth for excessive wear.  

2. Inspect the sun gear to drive gear teeth for excessive wear.  

3. Replace the sun gear or drive gear if it is worn. Refer to 

Transfer Case Disassemble and Transfer Case Assemble .  

Rear output shaft bearing outer 
retaining ring

1. Inspect for the following conditions: 

z

Proper installation of the rear output shaft bearing 
retaining ring  

z

Excessive wear or damaged retaining ring groove in the 
rear case half  

2. Repair or replace the following components if found faulty: 

z

Properly install a new rear output shaft bearing outer 
retaining ring.  

z

Replace the rear case half if the retaining ring groove is 
excessively worn. 

Refer to Transfer Case Disassemble and Transfer Case 
Assemble . 

Cause

Correction

DEFINITION: A shudder, binding, or a crop-hop while turning, which may cause tire scuffing. 
Review the Symptoms - Transfer Case and perform the necessary inspections.
Intermittent shift 
lock up 
engagement

1. Shift the vehicle into 4LO Lock or 4HI Lock.  

2. Shift the vehicle from 4LO Lock or 4HI Lock to the 4HI mode.  

3. Drive the vehicle and inspect for the shift lock up staying engaged after shifting 

from the 4LO Lock or 4HI Lock to the 4HI Mode. If the shift lock up stays 
engaged after shifting from 4LO Lock or 4HI Lock, it will give a symptom of 
both axles driving without any speed difference between the axles. It is noticed 
by tire scuffing on dry pavement when turning.  

4. Drive the vehicle in reverse for a few feet.  

5. Drive the vehicle forward and inspect for the shift lock up staying engaged. If 

the shift lock up disengaged after driving the vehicle in reverse this is normal 
and no further action is required.  

6. Advise the customer to drive the vehicle in reverse for a few feet if the shift lock 

up does not disengage after shifting out of 4LO Lock or 4HI Lock.  

Planetary 
differential

1. Inspect the planetary differential pinion gears for the following conditions: 

z

Chipped, bent or deformed teeth  

 

2004 Hummer H2 

2004 DRIVELINE/AXLE Transfer Case - BW 4484 - Hummer H2