Hummer H1 (2006+). Manual — part 208

5-72

Transmission/Transfer Case

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Figure 5-78: Input Gear Snap Ring Installation

Figure 5-79: Front Retainer Seal Installation

INPUT
GEAR

SHAFT

INPUT GEAR

BEARING

SNAP RING

FRONT

RETAINER

TOOL

J–33831

10-1-08

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Transmission/Transfer Case 5-73

5745804

Figure 5-80: Front Retainer Installation

Figure 5-81: Assembling Low Range Fork and Hub

Figure 5-82: Engaging Low Range Fork Pin in Shift Sector

9.

Check the condition of the tone wheel on the mainshaft. Replace the wheel if the teeth are chipped, cracked or broken.

10. Coat the needle bearing surface of the mainshaft with petroleum jelly. Then install the first spacer, 53 needle bearings and the

remaining spacer. Use extra petroleum jelly to hold the needle bearings in place (Figure 5-86).

11. Install the differential on the mainshaft. Verify that the needle roller bearings were not displaced before proceeding (Figure

5-87).

INPUT
GEAR

FRONT

RETAINER

HUB

PADS

LOW

RANGE

FORK

LOWER

SLOT

SHIFT

SECTOR

LOW

RANGE

FORK

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5-74

Transmission/Transfer Case

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12. Install the differential snap ring (Figure 5-88).

13. Install the intermediate clutch shaft. Be sure the shaft is fully seated (Figure 5-89).

14. Install the clutch shaft thrust ring and the snap ring (Figure 5-90).

Figure 5-83: Installing Mainshaft Gear In Front Case

Figure 5-84: Differential Pinion and Sprocket Gear Installation

MAINSHAFT

GEAR

DIFFERENTIAL

FRONT CASE

THRUST

WASHERS (6)

SHORT

PINION (3)

THRUST

WASHERS (6)

SPROCKET

GEAR

MAINSHAFT

GEAR

FRONT

CASE

LONG

PINION (3)

10-1-08

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Transmission/Transfer Case 5-75

5745804

Figure 5-85: Assembling Differential Front/Rear Cases

Figure 5-86: Mainshaft Bearing Roller Installation

CASE

ALIGNMENT

MARKS

FRONT

CASE

REAR

CASE

BEARING
SPACERS

NEEDLE ROLLER

BEARINGS

(HOLD IN PLACE

WITH PETROLEUM

JELLY)

10-1-08