Hummer H1 (2006+). Manual — part 203

5-52

Transmission/Transfer Case

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Figure 5-34: Drive Sprocket Snap Ring Removal/Installation

Figure 5-35: Drive Sprocket Removal

DRIVE

SPROCKET

SNAP RING

DRIVE

SPROCKET

DRIVE

SPROCKET

DRIVE

CHAIN

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Transmission/Transfer Case 5-53

5745804

Figure 5-36: Front Shaft and Driven Sprocket Removal

15. Remove the range lever nut, washer and the lever from the sector shaft (Figure 5-37).

Figure 5-37: Range Lever Mounting

16. Remove the detent plug, spring and the plunger (Figure 5-38).

17. Remove the oil cooler attaching nuts and the washers. Then remove the cooler, support bracket and the O-rings (Figure 5-38).

18. Remove the shift rail (Figure 5-39).

DRIVEN

SPROCKET

FRONT

OUTPUT

SHAFT

SECTOR SHAFT

RANGE LEVER

WASHER

NUT

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5-54

Transmission/Transfer Case

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Figure 5-38: Oil Cooler and Detent Plug, Spring, Plunger Removal

Figure 5-39: Shift Rail Removal/Installation

19. Remove the mainshaft, differential and the mode fork as an assembly (Figure 5-40).

OIL COOLER

O-RING

FRONT CASE

PLUNGER

SPRING

DETENT

PLUG

SUPPORT

BRACKET

SHIFT

RAIL

MODE

FORK

ASSEMBLY

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Transmission/Transfer Case 5-55

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Figure 5-40: Mainshaft, Differential and Mode Fork Removal

20. Remove the mode fork and the sleeve from the mainshaft (Figure 5-41). Note the position of the sleeve for installation

reference. DO NOT disassemble the fork assembly. Only the fork pads are serviceable.

21. Remove the snap ring that secures the intermediate clutch shaft on the mainshaft (Figure 5-42).

Figure 5-41: Mode Fork and Sleeve Removal

MODE FORK

ASSEMBLY

MAINSHAFT AND

DIFFERENTIAL

ASSEMBLY

MODE

FORK

ASSEMBLY

MAINSHAFT

MODE

SLEEVE

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