Hummer H1 (2006+). Manual — part 255

b.

If the pressure is above 230 psi, (1585 kPa), either a hose is restricted or a problem exists within the gear.

c.

If the flow is greater than 1.7 gpm and the pressure is less than 230 psi, continue the test.

9.

Partially close the analyzer valve, allow pressure to build to 700 psi (4827 kPa), and record the flow rate.

a.

If the flow rate decreases by more than 1 gpm (3.7 L/minute) from the reading in step 8, the pump is at fault.

b.

If the flow rate remains about the same, continue test.

10. Completely close and partially open the analyzer valve three times in succession. Note and record the maximum pressures

each time.

CAUTION: Do not close the analyzer valve for more than 3-4 seconds at a time. Longer periods will result in rapid fluid overheat
and pump damage.

Figure 8-31: Analyzer Pressure Test Connections

11. If the pump maximum pressures recorded in step 10 were less than 1200 psi (8274 kPa), the pump is at fault. However, if the

pressures are at, or above the specified limit, continue with the test.

12. Increase the engine speed to 1500 rpm and record the flow rate.

a.

If the flow rate remains within 1 gpm of flow recorded in step 8, continue the test.

b.

If the flow rate drops by more than 1 gpm (3.7L/ minute), the pump control valve is faulty.

13. Turn the steering wheel lightly against each of the stops and record the maximum pressure.

a.

If the pressure at each of the stops is about the same as recorded in step 10, and the flow drops to 0.5 gpm (1.85 L/min.),
the internal limit plungers must be adjusted. These limit plungers act as a pressure relief just prior to system contact with
the mechanical stops.

14. Turn the steering wheel to the right, release it., and observe the analyzer gauge. Then turn the wheel to the left, release it, and

observe the gauge again.

a.

If the gauge needle indicates normal pressure then snaps back as the wheel is released. Continue the test.

b.

If the gauge indicates normal pressure but the needle is slow to return when the wheel is released, the steering gear valve
body or the spool is sticking. A overhaul will be required to correct the problem.

15. If the gear and the pump test OK but a problem still exists, check for fluid contamination. Draw off a sample with a suction

gun and empty the sample in a glass container. Look for burned fluid, foreign material, fluid layering (fluid separates into two
layers), foreign material/metal particles in the fluid. Any of these conditions will cause gear and pump problems. Flushing the
system with new fluid may correct the problem.

FITTING

ANALYZER

ADAPTERS

J-44721

____________________________________________________________

Steering System 8-37

5745804

16. If the fluid condition is OK but a problem still exists, a problem may exist in the steering linkage, tires/wheels, or suspension

part. Further diagnosis will be required.

POWER STEERING SYSTEM FLUSHING

The power steering system can be flushed but only when the fluid does not contain metal particles, foreign material, or debris from
a gear or pump failure. Flushing is recommended only under the following circumstances:

• incorrect fluid added to system

• system filled with incorrect fluid

• water in the fluid

• burned, overheated fluid

Flushing Procedure

1.

Raise the front wheels just enough for them to turn freely.

2.

Disconnect the fluid return line at the pump. Then plug the pump return port with a rubber cap and the hose clamp.

3.

Position and secure the pump return line in a drain pan.

4.

Have a container of fresh power steering fluid handy. The pump reservoir will need refilling as the old fluid is pumped into the
drain pan.

5.

Start and run the engine at curb idle speed.

6.

Have a helper slowly turn the steering wheel back and forth about 3/4 turn in each direction.

7.

Continue the procedure until only the fresh fluid comes out of the return line.

8.

Stop the engine, reconnect the pump return line, and add power steering fluid as needed.

9.

Purge the air from the system. Refer to the procedure in this section.

10. Stop the engine and check the fluid level and condition. Repeat the flushing procedure if any old fluid is still evident in

reservoir fluid.

Steering Pump Flow Rates and Operating Pressures

NOTE: The pump output pressures are controlled by the pump relief valve setting

Minimum Flow Rate In Gallons/Liters Per Minute =

1.7gpm 6.4 liters/min) @ 465 rpm

Maximum Flow Rate In Gallons/Liters Per Minute =

3.5 to 3.9 gpm (13.2 to 14.7 liters/min) @ 1500 rpm

Minimum Pump Output Pressure

1200 psi (8274 kPa)

Maximum Pump Output Pressure:

1575 psi (10859 kPa)

8-38

Steering System

_____________________________________________________________

ESSENTIAL TOOLS

Procure from Kent-Moore.

SPECIAL TOOLS

Procure from Kent-Moore.

Tool

Description

J-44721-15

Adapter Fittings (used with J–44721)

CH-47965

Puller, Pitman Arm

J–44721

Power Steering System Analyzer

J–8092

Universal Driver Handle

Tool No.

Description

J–24319-B

Universal Steering Linkage Puller

J–25033-C

Pump Pulley Installer

J–25034-C

Pump Pulley Remover

CH-47975

Steering Linkage Separator

ADAPTER

J-44721-15

ANALYZER

J-44721

PULLER

CH-47965

DRIVER

J-8092

J–25033-C

J

–

25034-C

J

–

24319-B

CH-47975

________________________________________________________________________________

9-1

Section 9 Axles, Suspension and Frame

TABLE OF CONTENTS

Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3–9-38

Assembly and Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10
Assembly Replacement , Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-8
Assembly Replacement , Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10
Axle Assembly Repair
Pinion Depth Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-17
Cover Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6
ELockerTM (Option) Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3
Output Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6
Pinion Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7
Vent Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-31

Halfshaft

Boot Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-32

Propeller Shaft

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-35
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-37
U-Joint Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-38

Driveline Protection

Front Shield Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-80
Intermediate Shield Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-81
Rear Shield Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-83
Skid Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-79
Transfer Case Shield Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-82

Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-73–9-110

Airlift Brackets

Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-87
Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-88

Axle Support and Side Mounting Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-100
Brushguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-78
Bumper

Front Bumper and Towing Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-83
Front Bumper Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-85
Rear Bumper Outer Mounting Bracket and Tie Down Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-109

Control Arm Bracket, Upper Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-98
Crossmember, Front, Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-101, 9-105
Crossmember, Rear, Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-104
Engine Mount Bracket

Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-92
Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-93

Frame Extension Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-86
Front Body Mount Bracket

Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-94

Front Suspension

Brace Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-89