Hummer H1 (2006+). Manual — part 209
5-76
Transmission/Transfer Case
_______________________________________________
Figure 5-87: Installing Differential On Mainshaft
15. Install the mode sleeve in the mode fork. Replace the fork pads if worn or cracked. Do not reuse worn pads (Figure 5-91).
16. Install the assembled mode fork and the sleeve on the mainshaft. Then seat the sleeve in the differential (Figure 5-92).
17. Install the assembled mainshaft, differential, mode fork and sleeve. Be sure the mainshaft is seated in the input gear pilot
bearing, and that the mode fork pin is seated in the upper slot of the shift sector as shown (Figure 5-95).
Figure 5-88: Differential Snap Ring Installation
DIFFERENTIAL
MAINSHAFT
DIFFERENTIAL
SNAP RING
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Transmission/Transfer Case 5-77
5745804
Figure 5-89: Intermediate Clutch Shaft Installation
Figure 5-90: Intermediate Clutch Shaft Thrust Ring and Snap Ring Installation
18. Install the shift rail. Install the rail through the mode fork, range fork and into the case bore, and install the lock pin
(Figure 5-96).
DIFFERENTIAL
MAINSHAFT
INTERMEDIATE
CLUTCH SHAFT
CLUTCH SHAFT
THRUST RING
INTERMEDIATE
CLUTCH SHAFT
CLUTCH SHAFT
SNAP RING
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5-78
Transmission/Transfer Case
_______________________________________________
Figure 5-91: Installing Mode Sleeve in Mode Fork
Figure 5-92: Mode Fork and Sleeve Installation
19. Install the detent plunger, spring and the plug. Replace the O-ring on the plug, and tighten the plug to 12-18 lb-ft (16-24
N•m)(Figure 5-97).
20. Install the range lever on the sector shaft, then secure the lever with the washer and the nut (Figure 5-97). Tighten the nut to
20-25 lb-ft (27-34 N•m).
21. Install the shift sector shaft O-ring, and the nylon bushing. Use a thin wall socket to seat the O-ring and the bushing.
22. Install the support bracket onto the oil cooler, then install the sealing washers. Set the oil cooler into the transfer case front
half, and install the external hardware. Hand tighten only (Figure 5-93).
23. Align the upper support tab in the recess of the case, and ensure that the lower tab with the extra rivet installed rests on the
recessed casting. The lower tab is designed to have the rivet compressed between the recessed casting area of the front and the
rear transfer case halves when the halves are bolted together. Make sure that the tabs do not intrude into the machined mating
surface area of the transfer case halves. Do not bend the cooler when moving into position, damage to the manifold area could
occur from induced stress.While gently holding the cooler with a 3/4" wrench on the manifold, tighten the hardware to 15 lb-ft
(Figure 5-94).
NOTE: If the cooler is tightened incorrectly, the tension placed on the cooler assembly could cause cracking, leaking and loss of
transmission fluid into the transfer case assembly.
MODE FORK
ASSEMBLY
FORK
PADS
MODE
SLEEVE
DIFFERENTIAL
MAINSHAFT
MODE
SLEEVE
MODE FORK
ASSEMBLY
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Transmission/Transfer Case 5-79
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Figure 5-93: Transfer Case Cooler Support Bracket Installation
Figure 5-94: Transfer Case Cooler Support Tabs
COOLER SUPPORT
BRACKET
COOLER SEALING
WASHERS
TRANSFER CASE
OIL COOLER
TRANSFER CASE
FRONT HALF
MANIFOLD
CASE HALF
RECESS
HOLD WHEN
TIGHTENING
HARDWARE
UPPER COOLER
SUPPORT TAB
TIGHTEN
FIRST
LOWER
SUPPORT
TAB
10-1-08
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