Hummer H1 (2006+). Manual — part 259

9-14 Axles, Suspension and Frame

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Figure 9-15: Ring Gear Removal

14. Rotate the housing 90 degrees. Secure the cover to the housing with two bolts (Figure 9-16).

15. Remove the pinion nut and the pinion yoke from the pinion gear.

16. Drive the pinion gear out of the front pinion bearing.

17. Remove the cover, pinion gear, and the collapsible spacer from the housing. Discard the collapsible spacer.

18. Remove the pinion seal and the front pinion bearing from the housing. Discard the pinion seal.

Figure 9-16: Axle Housing

19. Rotate the front of the housing upward 90 degrees. Using the driver handle J–8092 and the bearing cup remover J–21786,

remove the pinion rear bearing cup and the pinion depth shim from the housing (Figure 9-17).

DIFFERENTIAL ASSEMBLY

RING GEAR

COVER

PINION

COLLAPSIBLE

HOUSING

FRONT

PINION SEAL

PINION YOKE

PINION NUT

SPACER

GEAR

PINION

BEARING

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Axles, Suspension and Frame 9-15

Figure 9-17: Pinion Rear Bearing Cup Removal

20. Rotate the housing 180 degrees. Using the driver handle J–8092 and the pinion front bearing cup remover J–21787, remove

the front pinion bearing cup from the housing (Figure 9-18).

Figure 9-18: Pinion Front Bearing Cup Removal

DRIVER

BEARING CUP

REMOVER

PINION

PINION REAR

BEARING CUP

HOUSING

DEPTH

SHIM

HANDLE

J–8092

J–21786

DRIVER

HANDLE

BEARING CUP

REMOVER

HOUSING

PINION FRONT

BEARING CUP

J–21787

J–8092

9-16 Axles, Suspension and Frame

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Figure 9-19: Differential Side Bearing Removal

Figure 9-20: Pinion Bearing Removal

21. Remove the two differential side bearings from the differential assembly (Figure 9-19).

22. Remove the rear pinion bearing from the pinion gear (Figure 9-20).

23. Remove the bearing from the output shaft (Figure 9-21).

Figure 9-21: Output Shaft Bearing Removal

Cleaning and Inspection

NOTE: Clean all the components. Examine for wear or damage and replace if necessary.

1.

Inspect the housing and all the threaded holes for damage. Repair any damaged threads with thread repair inserts. Replace the
axle assembly if the housing is damaged (Figure 9-22).

DIFFERENTIAL

SIDE BEARING

DIFFERENTIAL

ASSEMBLY

DIFFERENTIAL

SIDE BEARING

PINION GEAR

REAR PINION BEARING

BEARING

OUTPUT SHAFT

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Axles, Suspension and Frame 9-17

Figure 9-22: Housing

NOTE: The ring and pinion gears must be replaced as a matched set.

2.

Inspect the splines and gear teeth on the pinion gear and the ring gear for damage. Replace both pinion gear and ring gear if
either is damaged (Figures 9-23, and 9-24)

Figure 9-23: Ring Gear

Figure 9-24: Pinion Gear

3.

Inspect the splines and the sealing surfaces on the output flanges, pinion yoke and the output shaft for damage (Figures 9-25
9-26, and 9-27).

Figure 9-25: Output Flange

Figure 9-26: Pinion Yoke