Hummer H2. Manual - part 846

Fig. 10: Mounting Axle Shaft In Axle Shaft Clamp Swage (Typical) 
Courtesy of GENERAL MOTORS CORP.

 

2004 Hummer H2 

2003-04 DRIVE AXLES Axle Shafts - Front - Hummer H2

  

Fig. 11: Inspecting Inboard Stroke Position 
Courtesy of GENERAL MOTORS CORP. 

OUTER JOINT & SEAL 

Disassembly 

1. Use a hand grinder to cut through the swage ring. Use side cutters to cut off the small boot clamp. See 

Fig. 12 . Slide the boot down the axle shaft bar and away from the CV joint outer race. Wipe all grease 
away from the face of the CV joint. Find the axle shaft bar retaining snap ring, which is located in the 
inner race.  

2. Spread the snap ring ears apart using Snap Ring Pliers (or equivalent). Pull the CV joint and the CV joint 

boot from the axle shaft bar. Discard the old CV joint boot.  

3. Place a brass drift against the CV joint cage. Tap gently on the brass drift with a hammer in order to tilt 

NOTE:

Required Tools: Axle Shaft Seal Clamp Pliers (J-35910), Axle Shaft Clamp 
Swage Tool (J-36652) and Snap Ring Pliers (J-8059). 

 

2004 Hummer H2 

2003-04 DRIVE AXLES Axle Shafts - Front - Hummer H2

  

the cage. Remove the first chrome alloy ball when the CV joint cage tilts. Tilt the CV joint cage in the 
opposite direction to remove the opposing chrome alloy ball. See Fig. 12 . Repeat to remove all six of the 
balls.  

4. Pivot the CV joint cage and the inner race 90 degrees to the center line of the outer race. At the same 

time, align the cage windows with the lands of the outer race. Lift out the cage and the inner race. See 
Fig. 12 .  

5. Remove the inner race from the cage by rotating the inner race upward. Clean the inner and outer race 

assemblies, the CV joint cage and the chrome alloy balls thoroughly with cleaning solvent. Remove all 
traces of old grease and any contaminants.  

6. Dry all the parts. Check the CV joint assembly for unusual wear, cracks, or other damage. Replace any 

damaged parts. Clean the axle shaft bar. Use a wire brush to remove any rust in the seal mounting area 
(grooves).  

Fig. 12: Identifying Outer CV Joint (Rzeppa Type) Components 
Courtesy of GENERAL MOTORS CORP. 

Reassembly 

1. Inspect all of the parts for unusual wear, cracks, or other damage. Replace the CV joint assembly if 

necessary. Put a light coat of the recommended grease on the inner and the outer race grooves. See Fig. 
12 .  

2. Hold the inner race at 90 degrees to the centerline of the cage. Align the lands of the inner race with the 

windows of the cage. Insert the inner race into the cage, by rotating the inner race downward. See Fig. 
12 .  

3. Insert the cage and inner race into the outer race. Place a brass drift against the CV joint cage. Tap gently 

on the brass drift with a hammer in order to tilt the cage. Install the first chrome alloy ball when the CV 
joint cage tilts. Tilt the CV joint cage in the opposite direction to install the opposing chrome alloy ball. 
Repeat this process in order to install all six of the balls.  

4. Pack the CV joint boot and the CV joint assembly with the grease supplied in the kit. The amount of 

 

2004 Hummer H2 

2003-04 DRIVE AXLES Axle Shafts - Front - Hummer H2

  

grease supplied in this kit has been pre-measured for this application. Place the new small boot clamp 
onto the CV joint seal. Slide the CV joint boot onto the axle shaft bar. Position the small end of the CV 
joint boot into the joint boot groove on the axle shaft bar.  

5. Secure the small boot clamp using Axle Shaft Seal Clamp Pliers (or equivalent), a breaker bar, and a 

torque wrench. Tighten the small clamp to specifications. See TORQUE SPECIFICATIONS . See Fig. 
8 . Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. 
Gap dimension is .085" (2.15 mm).  

6. Pinch the new swage ring slightly by hand to distort it into an oval shape. Slide the distorted swage ring 

over the large diameter of the boot. Pull on the CV joint to verify engagement. Slide the large diameter of 
the CV joint boot, with the large swage ring in place, over the outside edge of the CV joint outer race.  

7. Clamp the CV joint boot tightly to the CV joint outer race with the large swage ring, using the following 

procedure: 

A. Mount the base of Axle Shaft Clamp Swage Tool in a vise. See Fig. 10 .  

B. Position the CV joint end (outboard end) of the axle shaft assembly in the bottom half of Axle 

Shaft Clamp Swage Tool.  

Align the CV joint boot, the CV joint assembly and the swage ring during this procedure.  

8. Install the top half of Axle Shaft Clamp Swage Tool onto the lower half of the tool, over the CV joint 

boot and the CV joint assembly. Align the swage ring and the swage ring clamp. Insert the bolts into Axle 
Shaft Clamp Swage Tool. Hand tighten the bolts until the bolts are snug. Tighten each bolt 180 degrees at 
a time. Alternate between the bolts until both sides of the top half of the Axle Shaft Clamp Swage Tool 
touch the bottom half of the tool. Loosen the bolts and remove the axle shaft assembly from Axle Shaft 
Clamp Swage Tool.  

TORQUE SPECIFICATIONS 

TORQUE SPECIFICATIONS 

SPECIAL TOOLS 

Application 

Ft. Lbs. (N.m) 

Hub Nut 

173 (235) 

Inboard Flange Nuts 

58 (79) 

Inner & Outer Joint Boot Small Clamp 

100 (136) 

Oil Pan Skid Plate Retaining Bolts 

15 (20) 

Stabilizer Shaft Insulator Bracket Bolts 

37 (50) 

Wheel Lug Nuts 

175 (240) 

INCH Lbs. (N.m)

Stabilizer Shaft-To-Lower Control Arm Nut 

89 (10) 

 

2004 Hummer H2 

2003-04 DRIVE AXLES Axle Shafts - Front - Hummer H2