Hummer H1 (2002+). Manual — part 143

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Axles, Suspension, and Frame 9-33

®

05745159

5.

Lubricate outside diameter of front pinion bearing cup
with lubricating oil. Using driver handle J–8092 and
bearing cup installer J–8611-01, install cup in housing.

6.

Install rear pinion bearing on pinion gear (Figure 9-83).

Figure 9-83: Pinion Rear Bearing and Pinion Gear

Installation

7.

Using pinion setting gauge set, install gauge block, rear
pinion bearing cup, rear pinion bearing, and pilot washer
on stud and secure with gauge block from set J–39524
(Figure 9-84).

Figure 9-84: Pinion Depth Setting Gauge

Installation

8.

Position stud assembly in housing and secure with front
pinion bearing, pilot washer, and nut. Tighten nut to 10 lb-
in (1.1 N•m). Rotate the assembly several revolutions to
seat the bearing and recheck the torque.

9.

Rotate front of housing downward 90 degrees. Assemble
arbor and two discs and install in housing (Figure 9-85).

Table 4 Pinion Variance Table - Inches (millimeters)

OLD

PINION

MARKING

NEW PINION MARKING

-4

-3

-2

-1

0

+1

+2

+3

+4

+4

+0.008

(0.20)

+0.007

(+0.18)

+0.006

(+0.15)

+0.005

(+0.13)

+0.004

(+0.10)

+0.003

(+0.08)

+0.002

(+0.05)

+0.001

(+0.03)

0
0

+3

+0.007

(+0.18)

+0.006

(+0.15)

+0.005

(+0.13)

+0.004

(+0.10)

+0.003

(+0.08)

+0.002

(+0.05)

+0.001

(+0.03)

0
0

-0.001

(-0.03)

+2

+0.006

(+0.15)

+0.005

(+0.13)

+0.004

(+0.10)

+0.003

(+0.08)

+0.002

(+0.05)

+0.001

(+0.03)

0
0

-0.001

(-0.03)

-0.002

(-0.05)

+1

+0.005

(+0.13)

+0.004

(+0.10)

+0.003

(+0.08)

+0.002

(+0.05)

+0.001

(+0.03)

0
0

-0.001

(-0.03)

-0.002

(-0.05)

-0.003

(-0.08)

0

+0.004

(+0.10)

+0.003

(+0.08)

+0.002

(+0.05)

+0.001

(+0.03)

0
0

-0.001

(-0.03)

-0.002

(-0.05)

-0.003

(-0.08)

-0.004

(-0.10)

-1

+0.003

(+0.08)

+0.002

(+0.05)

+0.001

(+0.03)

0
0

-0.001

(-0.03)

-0.002

(-0.05)

-0.003

(-0.08)

-0.004

(-0.10)

-0.005

(-0.13)

-2

+0.002

(+0.05)

+0.001

(+0.03)

0
0

-0.001

(-0.03)

-0.002

(-0.05)

-0.003

(-0.08)

-0.004

(-0.10)

-0.005

(-0.13)

-0.006

(-0.15)

-3

+0.001

(+0.03)

0
0

-0.001

(-0.03)

-0.002

(-0.05)

-0.003

(-0.08)

-0.004

(-0.10)

-0.005

(-0.13)

-0.006

(-0.15)

-0.007

(-0.18)

-4

0
0

-0.001

(-0.03)

-0.002

(-0.05)

-0.003

(-0.08)

-0.004

(-0.10)

-0.005

(-0.13)

-0.006

(-0.15)

-0.007

(-0.18)

-0.008

(-0.20)

PINION GEAR

REAR PINION

BEARING

GAUGE

PILOT

REAR

PINION

BEARING

WASHER

BLOCK

REAR PINION

BEARING CUP

GAUGE

BLOCK

STUD

FRONT

PINION

BEARING

PILOT

WASHER

9-34

Axles, Suspension, and Frame

_________________________________________

®

10. Install two bearing caps and four bolts in housing and

finger tighten bolts.

11. Install the dial indicator on the arbor post. Push the dial

indicator downward until the needle rotates approximately
one full turn clockwise. Tighten the dial indicator in this
position and recheck.

Figure 9-85: Positioning J–39524 Arbor and Discs

In Housing

12. Rotate the gauge shaft slowly back and forth until the dial

indicator reads the greatest deflection. At the point of
greatest deflection, set the dial indicator to zero. Repeat
the rocking action of the gauge shaft to verify the gauge
setting (Figure 9-86).

Figure 9-86: Gauge Setting

13. After the zero setting is obtained, rotate the gauge shaft

until the dial indicator plunger does not touch the gauge
block.

14. Record the dial indicator reading. Example: If the pointer

moved counterclockwise and stops between 0 and 11, add
100 inches to measurement for shim thickness. If the
pointer moves counterclockwise and stops between 84 and
99, correct shim thickness is indicated.

15. This reading indicates the shim thickness required for a

pinion etched with a zero (0) on the pinion head. If the
pinion being installed has a plus (+) or minus (-) etching,
then an adjustment of the shim thickness is required.
Example: If a pinion is etched +3, then 0.003 inches less
shim thickness is required. Subtract 0.003 inches from the
indicator reading. If a pinion is etched -3, then 0.003
inches more shim thickness is required. Add 0.003 inches
to the indicator reading.

16. Remove dial indicator from arbor (Figure 9-85).

17. Remove four bolts, two bearing caps, discs, and arbor

from housing.

18. Remove nut, pilot washer, front pinion bearing, and stud

assembly from housing (Figure 9-87).

Figure 9-87: Pinion Front Bearing and Depth Tool

Removal

19. Remove gauge block, pilot washer, rear pinion bearing,

rear pinion bearing cup, and gauge block from stud.

20. Note pinion depth variance marked on pinion gear. If

number is preceded by a plus (+) sign, add that amount in
thousands to standard setting of 2.547 in. (6.46 cm). If
number is preceded by minus (-) sign, subtract that amount
in thousands from standard setting of 2.547 in. (6.46 cm).
The result of this addition or subtraction is desired pinion
depth. Record for reference (Figure 9-88).

DIAL

INDICATOR

ARBOR

ARBOR

POST

BEARING

CAP

DISC

J–8001

PINION
SETTING
KIT J–39524

DIAL

INDICATOR

GAUGE
BLOCK

INDICATOR

PLUNGER

GAUGE

BLOCK

PILOT

WASHER

RING PINION

BEARING CUP

GAUGE

BLOCK

FRONT PINION

BEARING

PILOT

WASHER

REAR PINION

BEARING

STUD

________________________________________

Axles, Suspension, and Frame 9-35

®

05745159

Figure 9-88: Pinion Depth Variance Number

Location

21. Subtract desired pinion depth (step 14) from total

measured pinion depth (step 15). Result of this subtraction
is correct pinion depth shim thickness.

22. Lubricate pinion front bearing and pinion seal with gear

oil. Using yoke seal installer, install pinion front bearing
and pinion seal in housing (Figure 9-89).

Figure 9-89: Pinion Seal Installation

23. Rotate housing 180 degrees. Lubricate outside diameter of

pinion rear bearing cup with gear oil (Figure 9-90).

NOTE:

If pinion shim is beveled, be sure beveled side faces

bottom of bearing cup bore.

Figure 9-90: Pinion Rear Bearing Installation

24. Using driver handle J–8092 and bearing cup installer

J–8608, install correct thickness pinion shim and pinion
rear bearing cup in housing.

25. Rotate housing 90 degrees. Lubricate rear pinion bearing

with gear oil (Figure 9-91).

PINION GEAR

PINION DEPTH

VARIANCE NUMBER

SEAL INSTALLER J–29162

PINION FRONT

BEARING

HOUSING

PINION SEAL

DRIVER

HANDLE

REAR PINION

BEARING CUP

INSTALLER

BEARING CUP

HOUSING

PINION SHIM

J–8092

TOOL J–8608

9-36

Axles, Suspension, and Frame

_________________________________________

®

Figure 9-91: Rear Pinion Bearing Location

CAUTION: Collapsible spacer controls pinion bearing pre-
load. Do not reuse old spacer, or pinion bearing damage may
result.

26. Install collapsible spacer on pinion gear and install pinion

gear in housing.

27. Install pinion yoke on pinion gear with pinion nut.

CAUTION: Do not exceed specified preload torque on pinion
bearings. Do not loosen locknut to relieve the preload torque
or pinion bearing damage may result. If specified torque is ex-
ceeded, remove pinion gear and replace collapsible spacer
and locknut and adjust preload again.

28. Tighten pinion nut only enough to remove end play and

seat pinion bearings in housing. Rotate pinion yoke while
tightening to seat bearings evenly.

29. Measure torque required to rotate pinion gear. Correct

pinion bearing preload torque is 17-25 lb-in (2-3 N•m)
with new bearings and 10-15 lb-in (1-2 N•m) with used
bearings.

30. Continue to tighten pinion nut in small increments until

pinion bearing preload torque meets specifications.

31. Install two side bearings on differential assembly

(Figure 9-92).

Figure 9-92: Side Bearing Installation

NOTE:

Side bearing shims are available in thickness from

0.077-0.117 in. (1.96-2.97 mm) in increments of 0.001 in.
(0.025 mm).

32. Rotate housing downward 90 degrees. Install side bearing

cups and side bearing shims on side bearings. Use 0.080
in. (2 mm) shims as a starting point (Figure 9-93).

Figure 9-93: Side Bearing Cup and Shim

Installation

PINION REAR

BEARING

PINION GEAR

COLLAPSIBLE

HOUSING

PINION YOKE

PINION NUT

SPACER

SIDE BEARING

DIFFERENTIAL

ASSEMBLY

SIDE

BEARING

BEARING CAP

BEARING

HOUSING

BEARING

SHIM

SIDE

DIFFERENTIAL

ASSEMBLY

SIDE

CUP

SHIM

BEARING

BEARING

CUP