Hummer H2. Manual - part 931

Fig. 97: Differential Side Gears & Thrust Washers 
Courtesy of GENERAL MOTORS CORP. 

9. Remove the differential side gears and thrust washers. 

Mark the differential side gears and thrust washers left and right. 

DIFFERENTIAL CASE BEARINGS INSPECTION 

IMPORTANT:

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When replacing the worn or cracked bearings and the cups, replace 
the bearings in sets.  

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The low mileage bearings may have very small scratches and pits on 
the rollers and the bearing cups from the initial preload. 

Do not replace a bearing for this reason. 

 

2004 Hummer H2 

2004 DRIVELINE/AXLE Front Drive Axle - Hummer H2

  

1. Inspect the bearings for smooth rotation after oiling.  

2. Inspect the bearing rollers for wear.  

3. Inspect the bearing cups for the following conditions: 

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Wear  

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Cracks  

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Brinelling  

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Scoring  

DIFFERENTIAL CASE AND GEARS INSPECTION 

1. Inspect the following components for excessive wear and/or fit: 

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The pinion gear shaft  

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The thrust washers  

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The differential case for wear, cracks and scoring  

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The fit of the pinion gear shaft in the differential case  

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The fit of the differential side gears in the differential case  

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The fit of the side gears on the axle shafts  

2. Inspect the teeth of the pinion gears and the differential side gears for the following conditions: 

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Wear  

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Cracks  

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Scoring  

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Spalling  

3. Replace any worn or poor fitting components as necessary.  

PINION AND RING GEAR INSPECTION 

1. The ring and pinion gears are matched sets and must be replaced any time a replacement of either is 

necessary.  

2. Inspect the pinion and the ring gear teeth for the following conditions: 

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Cracking  

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Chipping  

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Scoring  

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Excessive wear  

3. Inspect the pinion gear splines for wear.  

4. Inspect the pinion flange splines for wear.  

5. Inspect the fit of the pinion flange on the pinion gear.  

6. Inspect the sealing surface of the pinion flange for nicks, burrs, or rough tool marks which will damage 

the inside diameter of the pinion seal and result in an oil leak.  

7. Inspect all of the parts for wear and replace as necessary. 

 

2004 Hummer H2 

2004 DRIVELINE/AXLE Front Drive Axle - Hummer H2

  

THRUST WASHERS, SHIMS, AND ADJUSTER SLEEVES INSPECTION

1. Inspect the shims and the thrust washers for cracks and chips. 

The damaged shims should be replaced with an equally sized service shim. 

2. Inspect the adjuster sleeves for damaged threads. Replace if required.  

DIFFERENTIAL CASE ASSEMBLY ASSEMBLE 

Tools Required 

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J 8092 Universal Driver Handle - 3/4 in - 10. See Special Tools and Equipment .  

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J 29710 Differential Side Bearing Installer. See Special Tools and Equipment .  

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J 36597 Side Bearing Puller Pilot - 9.25 in Axle  

Fig. 98: Differential Side Gears & Thrust Washers

 

2004 Hummer H2 

2004 DRIVELINE/AXLE Front Drive Axle - Hummer H2

  

Courtesy of GENERAL MOTORS CORP.

1. Install the thrust washers and the differential side gears into the differential case. 

If the same differential side gears and the thrust washers are being used, install the gears and the washers 
to the original locations. 

Fig. 99: Differential Pinion Gears & Thrust Washers 
Courtesy of GENERAL MOTORS CORP. 

2. Install the differential pinion gears by performing the following steps: 

1. Position both pinion gears between the differential side gears directly opposite of each other.  

2. Rotate the differential side gears until the pinion gears are opposite the opening in the differential 

case in line with the pinion shaft opening.  

3. Install the thrust washers in between the pinion gear and differential case using a hammer and brass drift. 

4. Install the differential side gear spacers. 

 

2004 Hummer H2 

2004 DRIVELINE/AXLE Front Drive Axle - Hummer H2