Hummer H1 (2006+). Manual — part 262

9-26 Axles, Suspension and Frame

__________________________________________

Figure 9-44: Side Bearing Cup and Shim Installation

33. Install the differential assembly, bearing cups and the shims in the housing.

34. Install the two bearing caps and the four bolts in the housing. Snug the bolts.

35. Mount the dial indicator on the housing and position the indicator to read off the ring gear mounting surface of the differential

assembly (Figure 9-45).

Figure 9-45: Dial Indicator Positioning For Case Runout Check

36. Pry between the differential assembly and the bearing cap on one side of the indicator. Pry on the opposite side to read the end

play.

BEARING CAP

BEARING

HOUSING

BEARING

SHIM

SIDE

DIFFERENTIAL

ASSEMBLY

SIDE

CUP

SHIM

BEARING

BEARING

CUP

RING GEAR

FLANGE OF CASE

DIAL INDICATOR

_________________________________________

Axles, Suspension and Frame 9-27

Figure 9-46: Ring Gear Guide Pin Installation

37. The amount read on the indicator is the shim thickness that should be added to the side bearing shims to arrive at zero end

play. Add the necessary shims and repeat the procedure to ensure accuracy.

38. Tighten the four bolts to 55-70 lb-ft. (75-95 N•m).

39. Rotate the differential assembly and check the runout. Runout should not exceed 0.002 in. (0.05 mm).

40. Remove the dial indicator from the housing.

NOTE: Tag the shims and the bearing cups for assembly.

41. Remove the four bolts, two bearing caps, bearing cups, shims and the differential assembly from the housing (Figure 9-47).

42. Install the four guide pins in the ring gear (Figure 9-46).

DIFFERENTIAL

CASE

RING GEAR

GUIDE PIN

9-28 Axles, Suspension and Frame

__________________________________________

Figure 9-47: Differential Assembly Mounting

43. Support the ring gear with wood blocks in the press.

44. Press the differential assembly on the ring gear.

45. Remove the four guide pins from the ring gear.

46. Install the ring gear on the differential assembly with the eight bolts. Tighten the bolts to 95-115 lb-ft. (129-156 N•m).

47. Install the side bearing shims, previously selected to remove the differential assembly side play, slide the bearing cups and the

differential assembly in the housing (Figure 9-47).

48. Install the two bearing caps in the housing with the four bolts. Tighten the bolts to 55-70 lb-ft. (75-95 N•m).

49. Attach the dial indicator to the housing and position the indicator to read off the drive side of the ring gear tooth at a right angle

(Figure 9-48).

BEARING

BEARING

DIFFERENTIAL

BEARING

BEARING

BEARING SHIM

HOUSING

CUP

SHIM

CAP

ASSEMBLY

CUP

_________________________________________

Axles, Suspension and Frame 9-29

Figure 9-48: Checking Ring Gear Backlash

NOTE: Backlash must be checked at four equally spaced points on ring gear and must not vary more than 0.002 in. (0.05 mm) be-
tween four points checked.

50. Move the ring gear back and forth while holding the pinion yoke stationary. Note the backlash registered on the indicator.

51. Ring gear backlash should be 0.005-0.009 in. (0.13-0.23 mm) with 0.008 in. (0.20 mm) desired. If the backlash must be

adjusted perform steps 52 through 55, if not go to step 56.

NOTE: Tag the shims and bearing cups for assembly.

52. Remove the four bolts, two bearing caps, bearing cups, shims and the differential assembly from the housing (Figure 9-47).

NOTE: The following example will explain the procedure for adjusting backlash: If side play was removed using 0.090 in. (2.29
mm) shims on each side totaling 0.180 in. (4.57 mm) and backlash, when checked, is found to be 0.011 in. (0.28 mm), add 0.004 in.
(0.10 mm) to shim on ring gear side and subtract 0.004 in. (0.10 mm) from shim on opposite side to correct backlash. This will re-
sult in 0.094 in. (2.39 mm) shim on ring gear side and 0.086 in. (2.18 mm) shim on other side. Backlash will be approximately
0.007-0.008 in. (0.18 to 0.20 mm). Total Shim Thickness remains 0.180 in. (4.57 mm).

53. To increase the backlash, install a thinner shim on the ring gear side and a thicker shim on the opposite side. To decrease the

backlash, install a thicker shim on the ring gear side and a thinner shim on the opposite side. Do not change the total shim
thickness.

54. Install the shims, bearing cups, differential assembly and the bearing caps in the housing and secure with the four bolts.

Tighten the bolts to 55-70 lb-ft. (75-95 N•m).

55. Mount the dial indicator and recheck the backlash. If necessary, repeat steps 52 through 54.

56. Remove the four bolts, bearing caps, bearing cup, shims and the differential assembly from the housing. Tag the shims and the

bearing cup for assembly.

57. Install the axle housing spreader into the holes in the axle holding fixture adapters and install the dial indicator to read from

each end of the housing. The indicator must have preload setting of 0.020 in. (0.50 mm) (Figure 9-49).

RING GEAR TOOTH

RING GEAR

HOUSING

PINION YOKE

DIAL INDICATOR J–8001