Hummer H1 (2006+). Manual — part 409

13-10

Accessories

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Figure 13-15: Intermediate Ring Gear and Gear Housing

2.

Install the retaining rings in the gear housing.

3.

Apply grease to the clutch lever hole and install the O-ring seal and the clutch lever in the gear housing.

4.

Install the detent ball, spring, and the detent spacer in the gear housing.

5.

Apply aircraft grease to the output gear carrier, intermediate gear carrier, and the input gear carrier assembly (Figure 13-16).

Figure 13-16: Gear Carriers

6.

Install the input gear carrier assembly in the gear housing.

NOTE: Be sure the ring gear engages in the gear housing.

7.

Install the gasket and the output ring gear on the gear housing.

8.

Install the intermediate gear carrier on the gear housing.

9.

Install the output gear carrier on the intermediate gear carrier.

10. Install the gasket on the output ring gear (Figure 13-17).

O- RING

CLUTCH

LEVER

DETENT

BALL

SPRING

DETENT

SPACER

INTERMEDIATE

RING GEAR

RETAINING

RING

STEEL

BALLS

GEAR

HOUSING

SEAL

OUTPUT

GEAR

OUTPUT

RING GEAR

INTERMEDIATE

GEAR CARRIER

GASKET

INPUT

GEAR CARRIER

ASSEMBLY

GEAR

HOUSING

SUN

GEAR

CARRIER

6-1-05

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Accessories 13-11

5745804

Figure 13-17: Gear Train Assembly

NOTE: Ensure the spline on the drum support engages in the output ring gear.

11. Install the gear end drum support on the output ring gear and the gear housing.

12. Secure the gear housing assembly to the drum support with the ten socket-head cap screws. Tighten the hex-head screws to

100 lb-in. (11 N•m).

13. Turn the gear train assembly over with the drum support facing up.

14. Install the driveshaft in the gear train assembly (Figure 13-17).

15. Apply grease to the drum bushings, seals, and the output spline.

Figure 13-18: Thrust Washers and Brakes

16. With the drum horizontal, install the brake into the drum (Figure 13-18).

17. Tighten the brake retaining set screw to 18-22 ft-lb (24-30 N•m) torque.

18. Install the two nylon thrust washers on the drum.

19. Install the drum assembly on the gear train assembly. Rotate the drum assembly as needed to engage the driveshaft, brake, and

the output spline (Figure 13-19).

GEAR TRAIN

ASSEMBLY

GASKET

DRIVE
SHAFT

GEAR END

DRUM SUPPORT

OUTPUT

RING GEAR

GEAR

HOUSING

NYLON THRUST

WASHER

BRAKE

DRUM

NYLON THRUST

WASHER

SET SCREW

BRAKE RETENSION

NOT REMOVABLE

TOLERANCE

RING

ASSEMBLY

6-1-05

13-12

Accessories

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Figure 13-19: Drum Assembly and Gear Train Assembly

20. Install the brake drive and the spacer to the motor shaft.

21. Install the motor end drum support on the drum assembly.

22. Install the motor on the motor end drum support, ensuring to engage the brake drive with the brake shaft end.

23. Install the three tie rods between the drum supports and secure with the six bolts. Tighten the bolts to 18 lb-ft (24 N•m).

Figure 13-20: Control Unit and Motor

24. Connect the three control leads to the terminals and secure with the nuts (Figure 13-21).

25. Secure the control to the motor with the clamps13-20.

26. Install the winch assembly and the winch cable.

MOTOR, 12 VDC

SHOWN WITHOUT CONTROL

SPACER (2)

DRUM SUPPORT

BRAKE

BRAKE

DRUM

ASSEMBLY

DRIVER

MOTOR END

DRUM SUPPORT

MOTOR END

TIE ROD

GEAR TRAIN

ASSEMBLY

00-S13-006

CONTROL

CLAMP

MOTOR

6-1-05

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Accessories 13-13

5745804

Winch Electric Thermal Switch/Brush Assembly Replacement

Removal

1.

Remove the winch and the winch cable.

NOTE: Tag the leads for assembly.

2.

Remove the three nuts and the control leads from the motor (Figure 13-21).

3.

Loosen the clamps and remove the control from the motor (Figure 13-22).

Figure 13-21: Control Leads

Figure 13-22: Control Unit and Motor

00-S13-005

CLAMP

DRUM SUPPORT

NUT

MOTOR

CONTROL

LEAD

TERMINAL

CONTROL

00-S13-009

MOTOR

CLAMP

SPACER

DRUM SUPPORT

CONTROL

6-1-05