Hummer H1 (2006+). Manual — part 258

9-10 Axles, Suspension and Frame

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Rear Axle Removal

CAUTION: Due to a torque bias ratio change, axle assemblies from previous model year vehicles must not be mixed with the cur-
rent assemblies.

1.

Remove the service brake rotors (Section 7).

2.

Remove the drainplug from the axle assembly. Allow the oil to drain and install the drainplug (Figure 9-8).

Figure 9-8: Rear Axle Assembly Mounting

3.

Remove the four bolts, two straps, and the rear propeller shaft from the pinion yoke.

4.

Remove the rear propeller shaft from the transfer case ( Figure 9-9).

5.

Remove the two bolts and washers securing the axle assembly to the mounting bracket (Figure 9-8).

NOTE: If the axle assembly is being reused and not replaced it is NOT necessary to remove the output flanges or the caliper sup-
port bracket assemblies.

6.

Remove the two locknuts, four O-ring seals and the two output flanges from the axle assembly. Discard the locknuts and the
O-ring seals.

WARNING: Axle assembly must be supported during removal and installation. Failure to do this may cause per-
sonal injury or damage to equipment.

7.

Support the axle assembly.

8.

Remove the four bolts and washers securing the axle assembly to the side mounting brackets.

9.

Lower the axle assembly slightly and disconnect the vent line from the axle assembly.

10. Remove the axle assembly.

11. Remove the four bolts and the two brake caliper adapters from the axle assembly.

VENT LINE

MOUNTING

RUBBER

OUTPUT

AXLE ASSEMBLY

BRAKE

DRAINPLUG

CALIPER

ADAPTER

FLANGE

WASHER

BRACKET

AXLE ASSEMBLY

SUPPORT BRACKET

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Axles, Suspension and Frame 9-11

Figure 9-9: Rear Propeller Shaft Removal

Rear Axle Installation

1.

Raise the axle assembly into place and connect the vent line.

NOTE: Washers are required when securing the rear axle assembly to the mounting bracket.

2.

Apply Loctite 272 (or equivalent) thread-locking compound to the tapped holes of the upper mounting point. Install the two
washers, bolts and the axle assembly to the mounting bracket and torque to 125-150 lb-ft. (169-203 N•m).

3.

Install the lower mounting bolts, nuts and washers and torque to 125-150 lb-ft. (169-203 N•m).

4.

Secure the two output flanges and the two washer seals to the axle assembly with the two locknuts. Tighten the locknuts to
165-195 lb-ft. (224-264 N•m).

5.

Install the rear propeller shaft in the transfer case Figure 9-9.

6.

Secure the rear propeller shaft to the pinion yoke with the four bolts and the two straps. Tighten the bolts to 12 lb-ft. (16 N•m)
Figure 9-9.

7.

Install the service brake rotors (Refer to section 7).

8.

Fill the axle assembly to the proper oil level (Refer to section 1).

Axle Assembly Repair

CAUTION: Due to a torque bias ratio change, differentials from previous model year vehicles must not be mixed with the current
assemblies.

Disassembly

1.

Remove the axle assembly.

2.

Loosen the locknut on the output shaft assembly (Figure 9-10).

TRANSFER CASE

PINION YOKE

STRAP

REAR

PROPELLER

SHAFT

9-12 Axles, Suspension and Frame

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Figure 9-10: Output Shaft Assembly Removal

3.

Using a slide hammer, remove the output shaft assembly from the axle assembly.

4.

Remove the locknut, seal washer, output flange and the output shaft seal from the output shaft Discard the seal washer, output
shaft seal and the locknut (Figure 9-11).

Figure 9-11: Output Shaft Assembly Breakdown

5.

Repeat steps 2 through 4 for the opposite side.

6.

Secure the two axle holding fixture adapters to the housing with the four bolts. Place the housing in the holding stand (Figure
9-12).

Figure 9-12: Axle Mounted In Holding Fixture

7.

Position the housing so the cover faces up. Remove the twelve bolts and the cover from the housing (Figure 9-12).

8.

Mark the bearing caps and the housing for assembly and remove the bearing caps (Figure 9-13).

AXLE ASSEMBLY

OUTPUT SHAFT ASSEMBLY

LOCKNUT

OUTPUT SHAFT

OUTPUT SHAFT SEAL

OUTPUT

FLANGE

SEAL

LOCKNUT

WASHER

DIFFERENTIAL

AXLE

AXLE HOLDING

FIXTURE J–3409-01

COVER

HOUSING

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Axles, Suspension and Frame 9-13

Figure 9-13: Housing Spreader Mounting

9.

Install the axle housing spreader J–3409-01 into the holes in the axle holding fixture adapters and install the dial indicator J–
8001 to read from each end of the housing as shown. Then set the dial indicator at 0.020 in. (0.5 mm).

CAUTION: Over-tightening of the axle housing spreader will damage the axle housing.

10. Spread the housing 0.010 in. (0.25 mm) and remove the dial indicator.

11. Remove the differential assembly, two bearing cups, and the shims from the housing (Figure 9-14). Tag the bearing shims and

the bearing cups for assembly.

Figure 9-14: Differential Assembly

12. Relieve the pressure on the axle housing spreader and remove from the housing.

CAUTION: To avoid damage, do not chisel or wedge the ring gear from the axle assembly.

13. Remove the eight bolts and ring gear from the differential assembly (Figure 9-15).

BEARING CAP

AXLE

HOUSING

SPREADER

HOUSING

DIAL INDICATOR

J–24385-01

J–8001

SHIM

BEARING CUP

DIFFERENTIAL BEARING

SHIM

AXLE HOUSING

HOUSING

ASSEMBLY

CUP

SPREADER J–3409-01