Hummer H1 (2006+). Manual — part 206

5-64

Transmission/Transfer Case

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Oil Pump

The oil pump is not a serviceable component. Replace the pump as an assembly if the gear teeth are worn, or if the pump has be-
come damaged.

Bearings and Seals

The transfer case seals should be replaced during overhaul. Use new seals in the oil pump, input gear bearing retainer, front case,
and extension housing. Also replace the yoke seal washer and detent plug O-ring.

FRONT OUTPUT SHAFT BEARING AND SEAL REPLACEMENT

1.

Remove the snap ring securing the front bearing in the front case (Figure 5-60).

2.

Tap the old bearing out rearward of the front case with plastic or raw hide mallet.

3.

Install a new bearing with tool handle J–8092, and the installer tool J–33833 (Figure 5-61).

4.

Lubricate the new bearing with Dexron III.

5.

Install the new shaft seal with seal installer J–38869 (Figure 5-62). Then lubricate the seal lip with Dexron III.

6.

Remove the front output shaft rear bearing from the rear case as follows:

a.

Clamp the rear case to a bench with wood blocks, and C-clamps.

b.

Pull the bearing using a slide hammer, adapter J–2619-01, and puller J–26369 (Figure 5-63).

c.

Install a new bearing with tool handle J–8092, and installer J–33832 (Figure 5-64). The rear bearing bore is chamfered at
the top. Install the bearing so it is flush with the chamfer lower edge.

CAUTION: Do not bottom the bearing in the bore. This will block the oil feed hole in the rear case bearing bore.

Figure 5-60: Front Output Shaft Front Bearing Snap Ring Removal/Installation

FRONT CASE

BEARING

SNAP RING

FRONT OUTPUT

SHAFT FRONT

BEARING

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Transmission/Transfer Case 5-65

5745804

Figure 5-61: Front Output Shaft Front Bearing Installation

Figure 5-62: Front Output Shaft Seal Installation

Figure 5-63: Front Output Shaft Rear Bearing Removal

TOOL

HANDLE

TOOL J–33833

J–8092

FRONT

OUTPUT

SHAFT

SEAL

TOOL J–38869

REAR CASE

FRONT OUTPUT

SHAFT REAR

BEARING

SLIDE HAMMER

TOOL

J–26369

J–2619-01

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5-66

Transmission/Transfer Case

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Figure 5-64: Front Output Shaft Rear Bearing Installation

INPUT GEAR BEARING REPLACEMENT

1.

Remove the old bearing from the interior of the front case as shown. Use tool handle J–8092, and tool J–29170 (Figure 5-65).

2.

Install the new bearing using tool handle J–8092, and tool J–29170 (Figure 5-66). Seat the bearing so the locating ring is
firmly seated against the case.

Figure 5-65: Input Gear Bearing Removal

Figure 5-66: Input Gear Bearing Installation

BEARING

TOOL

HANDLE

TOOL

J–33832

J–8092

BEARING

TOOL HANDLE

TOOL

J–29170

J–8092

BEARING

LOCATION

RING

NEW

BEARING

TOOL HANDLE

J–8092

TOOL

J–29170

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Transmission/Transfer Case 5-67

5745804

MAINSHAFT PILOT BEARING REPLACEMENT

1.

Remove the pilot bearing from the input gear with a slide hammer J–2619-01, and puller tool J–29369-1(Figure 5-67). Sup-
port the input gear on a vise, over a precut notch, or a hole in the workbench.

2.

Install a new pilot bearing in the gear with tool handle J–8092, and tool J–33829 (Figure 5-68). Seat the bearing flush with the
chamfer in the bearing bore.

Figure 5-67: Removing Mainshaft Pilot Bearing From Input Gear

Figure 5-68: Installing Mainshaft Pilot Bearing In Input Gear

EXTENSION HOUSING BUSHING AND SEAL REPLACEMENT

1.

Remove the old seal with a pry tool.

2.

Drive out the old bushing with tool handle J–8092, and tool J–33839 (Figure 5-69).

3.

Position the new bushing on the tool J–33839, and tap the bushing until flush with bushing bore.

4.

Install the new seal in the housing with J–33843, or a suitable size installer tool (Figure 5-70).

5.

Lubricate the seal lip with Dexron III or petroleum jelly.

INPUT
GEAR

TOOL

J–29369-1

SLIDE

HAMMER

J–2619-01

INPUT GEAR

TOOL

TOOL HANDLE

J–8092

J–33829

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