Hummer H3. Manual — part 1655

TRANSFER CASE CLUNK IN 4HI LOCK

Transfer Case Clunk in 4HI Lock

Refer to Cleaning and Inspection.

2. Inspect the planetary differential for deformation. Refer

to Cleaning and Inspection.

3. Replace the planetary differential assembly if it is faulty.

Refer to Transfer Case Disassemble and Transfer
Case Assemble.

Sun gears

1. Inspect the sun gears for the following conditions:

Gear tooth failure

Worn or galled thrust surfaces

Refer to Cleaning and Inspection.

2. Replace the sun gears if they are faulty. Refer to

Transfer Case Disassemble and Transfer Case
Assemble.

Thrust washers

1. Inspect the thrust washers for seizure to the planetary

differential.

2. Inspect the thrust washers for galling.

3. Replace the thrust washers if they are faulty and the

mating component if it is damaged. Refer to Transfer
Case Disassemble and Transfer Case Assemble.

Planetary differential not
timed properly

1. Inspect the planetary differential for being timed

properly. Refer to Transfer Case Assemble.

2. Properly time the planetary differential gears. Refer to

Transfer Case Assemble.

Cause

Correction

DEFINITION: During acceleration or deceleration, a clunk is heard or felt in the transfer
case while in the 4HI Lock range only.
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.

2007 Hummer H3

2007 TRANSMISSION Transfer Case - BW 4493/4494 - H3

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 Approximate Fluid Capacities.

Worn high speed teeth on
the range sleeve

1. Inspect for worn high speed teeth on the range sleeve.

Refer to Cleaning and Inspection.

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

Case Disassemble and Transfer Case Assemble.

Worn or missing input gear
thrust washer

Replace the worn or missing input gear thrust washer. Refer to
Transfer Case Disassemble and Transfer Case Assemble.

Worn or faulty planetary
differential

1. Inspect the planetary differential for the following

conditions:

Loose planetary differential splines to mainshaft
splines

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:

Properly installed rear output shaft bearing

2007 Hummer H3

2007 TRANSMISSION Transfer Case - BW 4493/4494 - H3

TRANSFER CASE CLUNK IN 4LO LOCK

Transfer Case Clunk in 4LO Lock

retaining ring

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:

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

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

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:

Excessively worn planetary gears

The planetary gears loose in the planetary carrier

2007 Hummer H3

2007 TRANSMISSION Transfer Case - BW 4493/4494 - H3

TRANSFER CASE CLUNK DURING ACCELERATION AND DECELERATION

Transfer Case Clunk during Acceleration and Deceleration

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

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.

Ring gear

1. Inspect the ring 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 Approximate Fluid Capacities.

Excessive clearance
between the slip yoke and

1. Inspect for the following conditions:

Worn slip yoke splines

2007 Hummer H3

2007 TRANSMISSION Transfer Case - BW 4493/4494 - H3