Hummer H1 (2002+). Manual — part 94

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Transmission/Transfer Case 5-175

®

05745159

Figure 5-149: Mode Fork and Sleeve Installation

19. Install detent plunger, spring, and plug. Replace O-ring on

plug before hand and tighten plug to 12-18 lb-ft (16-24
N•m) (Figure 5-154).

20. Install range lever on sector shaft, then secure lever with

washer and nut (Figure 5-154). Tighten nut to 20-25 lb-ft
(27-34 N•m).

21. Install shift sector shaft O-ring and nylon bushing. Use

thin wall socket to seat O-ring and bushing.

22. Install support bracket onto oil cooler, then install sealing

washers, set oil cooler into the transfer case front half and
install external hardware. Hand tighten only.
(Figure 5-150)

23. Align the upper support tab in the recess of the case and

ensure that the lower tab, the one with the extra rivet
installed, rests on the recessed casting. The lower tab is
designed to have the rivet compressed between the
recessed casting area of the front and rear transfer case
halves when the halves are bolted together. Make sure that
the tabs do not intrude into the machined mating surface
area of the transfer case halves. Do not bend the cooler
when moving into position, damage to the manifold area
could occur from induced stress.While gently holding the
cooler with a 3/4" wrench on the manifold, tighten
hardware to 15 lb-ft. (Figure 5-151)

NOTE:

If the cooler is tightened incorrectly, the tension

placed on the cooler assembly could cause cracking, leaking
and loss of transmission fluid into the transfer case assembly.

Figure 5-150: Transfer Case Cooler Support Bracket

Installation

Figure 5-151: Transfer Case Cooler Support Tabs

DIFFERENTIAL

MAINSHAFT

MODE

SLEEVE

MODE FORK

ASSEMBLY

9-S05-003.1

COOLER SUPPORT
BRACKET

COOLER SEALING
WASHERS

TRANSFER CASE
OIL COOLER

TRANSFER CASE

FRONT HALF

MANIFOLD

9-S05-002.2

CASE HALF

RECESS

HOLD WHEN
TIGHTENING

HARDWARE

UPPER COOLER

SUPPORT TAB

TIGHTEN

FIRST

LOWER

SUPPORT

TAB

4-1-00

5-176

Transmission/Transfer Case

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®

Figure 5-152: Mainshaft, Differential, and Mode Fork

Installation

Figure 5-153: Shift Rail Installation

24. Assemble driven sprocket and front output shaft. Use new

snap ring if old one is worn or distorted (Figure 5-155).

25. Install front output shaft and driven sprocket. Then install

drive chain (Figure 5-156).

26. Install drive sprocket. Slide sprocket down onto

mainshaft. Engage sprocket in chain and work it onto
mainshaft splines (Figure 5-156).

27. Secure drive sprocket to mainshaft with new snap ring. Be

sure snap ring is fully seated before proceeding
(Figure 5-157).

Figure 5-154: Range Cover and Shift Detent

Installation

28. Install new seal in oil pump with tool J–33835

(Figure 5-158).

29. Install new O-ring in oil pump inlet port. Then assemble

pump, pickup tube, connector hose and pickup screen
(Figure 5-159).

MODE FORK

ASSEMBLY

MAINSHAFT AND

DIFFERENTIAL

ASSEMBLY

SECTOR

UPPER SLOT

MODE FORK PIN

MODE

FORK

SHIFT

RAIL

LOCKNUT

WASHER

RANGE LEVER

DETENT

PLUNGER

SPRING

PLUG

SHIFT SECTOR SHAFT

4-1-00

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Transmission/Transfer Case 5-177

®

05745159

30. Position pump assembly in rear case. Be sure pickup

screen is seated in case notch as shown (Figure 5-160).

Figure 5-155: Front Output Shaft and Sprocket

Assembly

Figure 5-156: Drive Chain and Sprocket Installation

Figure 5-157: Securing Drive Sprocket to Mainshaft

31. Install magnet in front case pocket (Figure 5-161).

32. Apply 3/16 in. (5 mm) wide bead of Permatex Ultra Black

to sealing flange of front case. Be sure sealer encircles
each case bolt hole.

33. Align and install rear case on front case (Figure 5-162). Be

sure alignment dowel is seated and that oil pump is
properly engaged in mainshaft splines. Also be sure front
output shaft is seated in rear bearing and shift rail is seated
in rear case bore.

34. Install and tighten case bolts in diagonal pattern to 20-25

lb-ft (27-34 N•m).

DRIVEN SPROCKET

FRONT OUTPUT SHAFT

SNAP RING

DRIVE

SPROCKET

DRIVE

CHAIN

FRONT OUTPUT

SHAFT AND

DRIVEN SPROCKET

DRIVE

SPROCKET

DRIVE

SPROCKET

SNAP RING

4-1-00

5-178

Transmission/Transfer Case

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®

Figure 5-158: Oil Pump Seal Installation

Figure 5-159: Oil Pump and Pickup Component

Assembly

35. Install speedometer tone wheel and snap rings (Figure 5-163).

36. Install mainshaft bearing in rear retainer (Figure 5-164).

Use tool handle J–8092 and installer J33832.

Figure 5-160: Oil Pump Assembly Installation

Figure 5-161: Chip Magnet Installation

37. Apply 3/16 in. (5 mm) wide bead of Loctite 518, Permatex

Ultra Black, or Ultra Copper to flange surface of rear
retainer.

38. Align and install rear retainer (Figure 5-165). Install and

tighten retainer bolts to 22-25 lb-ft (30-34 N•m).

39. Install mainshaft bearing snap ring (Figure 5-165).

40. Apply 3/16 in. (5 mm) wide bead of Loctite 518, Permatex

Ultra Black, or Ultra Copper to extension housing flange.

41. Align and install extension housing on rear retainer

(Figure 5-166). Install and tighten housing bolts to 20-25
lb-ft (27-34 N•m).

42. Check seal contact surface of front yoke. Smooth surface

with 320-400 grit emery if necessary. Then lubricate seal
surface with Dexron III and Install yoke, new seal washer,
and new yoke nut. Tighten yoke nut to 130-200 lb-ft (176-
271 N•m). Use yoke tool J–8614-01 to hold yoke while
tightening nut (Figure 5-167).

OIL PUMP
HOUSING

TOOL

J–33835

OIL PUMP

OIL PICKUP TUBE

CONNECTOR

OIL

INLET PORT

O-RING

HOSE

PICKUP

SCREEN

OIL PUMP

REAR CASE

OIL PICKUP

SCREEN

CASE

PICKUP TUBE

NOTCH

CHIP

MAGNET

FRONT

CASE

POCKET

4-1-00