Hummer H1 (2006+). Manual — part 260

9-18 Axles, Suspension and Frame

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Figure 9-27: Output Shaft.

4.

Inspect all the bearings and the bearing cups for damage (Figure 9-28).

Figure 9-28: Bearing and Bearing Cup

5.

Inspect the differential assembly case for damage (Figure 9-29).

Figure 9-29: Differential Assembly

Pinion Depth Setting

NOTE: Pinion gear depth is the distance from the end face of the pinion to the center line of the output shafts. The dimension is
controlled by shims between pinion gear rear bearing cup and differential housing. The pinion gear is etched with two identifying
numbers. The first number identifies ring gear and pinion gear as a matched set, and the second number represents pinion depth
variance. The second number is preceded by a plus (+) or minus (-) which represents the amount the gear set varies from the stan-
dard setting of 2.547 in. (6.46 cm). If using original gear set, use original pinion depth shim as a starter shim and proceed to step 4.

1.

Measure the thickness of the original pinion depth shim and record for reference (Figure 9-30).

Figure 9-30: Pinion Depth Shim

2.

Check the pinion depth variance number marked on the old and the new pinion gears and record (Figure 9-31).

BEARING

BEARING

CUP

DIFFERENTIAL

ASSEMBLY

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Axles, Suspension and Frame 9-19

Figure 9-31: Pinion Depth Variance Number Location

NOTE: If the old pinion is marked -3 and the new pinion is marked +2, the procedure would be as follows: Refer to Old Pinion
Marking column at left. side of table and locate -3 in this column. Then read to right, across table, until under +2 in New Pinion
Marking column. The box where two columns intersect is amount of shim thickness change required. In this case, the number in
the intersecting box is -0.005 in. (0.13 mm) which represents the amount to be subtracted from the old shim thickness. If the box
number had been a (+) figure, this amount would be added to the old shim thickness. The actual pinion depth measurement must be
performed and final shim thickness adjusted as necessary. Pinion shims are available from 0.084-0.111 in. (2.13-2.82 mm) in incre-
ments of 0.0005 in. (0.0127 mm).

3.

Refer to the Old and the New Pinion Marking columns on the pinion variance table (Figure 9-33). Note on the table where the
old and new pinion depth variances intersect. This will determine amount to be added or subtracted from the original pinion
depth shim for desired pinion depth starter shim.

4.

Rotate the housing so the front pinion bearing cup bore faces up (Figure 9-32).

Figure 9-32: Pinion Front Bearing Cup Installation

PINION GEAR

PINION DEPTH

VARIANCE

NUMBER

DRIVER

HANDLE

BEARING CUP

INSTALLER

PINION FRONT

BEARING CUP

HOUSING

J–8092

J–8611-01

9-20 Axles, Suspension and Frame

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Figure 9-33: Pinion Variance Table

5.

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

6.

Install the rear pinion bearing on the pinion gear (Figure 9-34) with installer tool J-35237.

Figure 9-34: Pinion Rear Bearing and Pinion Gear Installation

7.

Using the pinion setting gauge set, install the gauge block, rear pinion bearing cup, rear pinion bearing and the pilot washer on
the stud and secure with the gauge block from the set J–39524 (Figure 9-35).

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

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Axles, Suspension and Frame 9-21

Figure 9-35: Pinion Depth Setting Gauge Installation

8.

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

9.

Rotate the front of the housing downward 90 degrees. Assemble the arbor and the two discs and install in the housing (Figure
9-36).

10. Install the two bearing caps and the four bolts in the housing finger tight.

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 9-36: 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 9-37).

GAUGE

PILOT

REAR

PINION

BEARING

WASHER

BLOCK

REAR PINION

BEARING CUP

GAUGE

BLOCK

STUD

FRONT

PINION

BEARING

PILOT

WASHER

DIAL

INDICATOR

ARBOR

ARBOR

POST

BEARING

CAP

DISC

J–8001

PINION

SETTING

KIT J–39524