Hummer H1 (2002+). Manual — part 90

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Transmission/Transfer Case 5-159

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05745159

Figure 5-90: Oil Pump O-ring Location

11. Remove drive sprocket snap ring (Figure 5-91).

12. Remove drive sprocket (Figure 5-92).

13. Remove drive chain.

14. Remove front output shaft and driven sprocket as

assembly (Figure 5-93).

Figure 5-91: Drive Sprocket Snap Ring Removal/

Installation

Figure 5-92: Drive Sprocket Removal

Figure 5-93: Front Shaft and Driven Sprocket

Removal

15. Remove range lever nut, washer and lever from sector

shaft (Figure 5-94).

OIL PUMP

INLET PORT

O-RING

DRIVE

SPROCKET

SNAP RING

DRIVE

SPROCKET

DRIVE

SPROCKET

DRIVE

CHAIN

DRIVEN

SPROCKET

FRONT

OUTPUT

SHAFT

5-160

Transmission/Transfer Case

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Figure 5-94: Range Lever Mounting

16. Remove detent plug, spring, and plunger (Figure 5-95).

17. Remove oil cooler attaching nuts and washers. Then

remove cooler, support bracket and O-rings (Figure 5-95).

18. Remove shift rail (Figure 5-96).

Figure 5-95: Oil Cooler and Detent Plug, Spring,

Plunger Removal

Figure 5-96: Shift Rail Removal/Installation

19. Remove mainshaft, differential, and mode fork as

assembly (Figure 5-97).

Figure 5-97: Mainshaft, Differential and Mode Fork

Removal

SECTOR SHAFT

RANGE LEVER

WASHER

NUT

OIL COOLER

O-RING

FRONT CASE

PLUNGER

SPRING

DETENT

PLUG

SUPPORT

BRACKET

SHIFT

RAIL

MODE

FORK

ASSEMBLY

MODE FORK

ASSEMBLY

MAINSHAFT AND

DIFFERENTIAL

ASSEMBLY

4-1-00

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Transmission/Transfer Case 5-161

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05745159

20. Remove mode fork and sleeve from mainshaft

(Figure 5-98). Note position of sleeve for installation
reference. Do not disassemble fork assembly. Only the
fork pads are serviceable.

21. Remove snap ring that secures intermediate clutch shaft

on mainshaft (Figure 5-99).

Figure 5-98: Mode Fork and Sleeve Removal

Figure 5-99: Intermediate Clutch Shaft Snap Ring

Removal/Installation

22. Remove intermediate clutch shaft and tabbed thrust ring

from mainshaft (Figure 5-100).

Figure 5-100: Clutch Shaft Removal

MODE

FORK

ASSEMBLY

MAINSHAFT

MODE

SLEEVE

SNAP RING

INTERMEDIATE

CLUTCH

SHAFT

MAINSHAFT

INTERMEDIATE

CLUTCH SHAFT

THRUST RING

SNAP RING

5-162

Transmission/Transfer Case

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23. Remove differential snap ring (Figure 5-101).

24. Remove differential from mainshaft (Figure 5-102).

25. Remove mainshaft needle roller bearings and spacers

(Figure 5-103).

Figure 5-101: Differential Snap Ring Location

Figure 5-102: Differential Removal

Figure 5-103: Mainshaft Bearing and Spacer

Removal

26. Slide low range fork pin out of shift sector. Then remove

low range fork and sleeve as assembly (Figure 5-104).

27. Remove shift sector.

28. Remove shift sector shaft bushing and O-ring

(Figure 5-105).

Figure 5-104: Range Fork and Sleeve Removal

DIFFERENTIAL

SNAP RING

DIFFERENTIAL

MAINSHAFT

MAINSHAFT

NEEDLE
ROLLER

BEARINGS

BEARING
SPACERS

PIN

LOW RANGE

FORK

SLEEVE

SHIFT

SECTOR