Hummer H2. Manual — part 2755

z

Debris embedded in the links

z

Worn teeth surfaces

3. Replace the chain if any of the above conditions are found.

4. Inspect the driven sprocket (3) and the drive sprocket (2) for the following conditions:

z

Chipped teeth

z

Excessively worn gear surfaces

Slight wear marks are normal.

z

Debris embedded in the root of the teeth

5. Inspect the drive sprocket (2) for the following conditions:

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Lockup shift engagement teeth for chipping

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Lockup shift engagement teeth for excessive wear

6. Inspect the drive sprocket bushing for the following conditions:

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Excessive wear

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Scoring

7. Replace the sprockets if any of the above conditions are found. The chain and sprockets may be replaced

separately.

Mainshaft

1. Clean the mainshaft in cleaning solvent.

2. Clean the mainshaft oil galleries (1) and air dry.

2004 Hummer H2

2004 DRIVELINE/AXLE Transfer Case - Overhaul - BW 4482-NR4

Fig. 63: Identifying Mainshaft Inspection Areas
Courtesy of GENERAL MOTORS CORP.

3. Inspect the bearing journals on the mainshaft for the following conditions:

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The front support bearing (2)

z

The drive gear bushing (4)

z

The front sun gear (5)

z

The rear support bushing (6)

„

Scoring

„

Pitting

„

Brinelling

„

Excessive wear

4. Inspect the mainshaft range collar splines (3) for damage or excessive wear. Witness marks at the location

of the gear is normal.

5. Replace the mainshaft if any of the above conditions are found.

Front Output Shaft

IMPORTANT: Do not attempt to smooth any roughness in the bearing journals.

2004 Hummer H2

2004 DRIVELINE/AXLE Transfer Case - Overhaul - BW 4482-NR4

Fig. 64: Front Output Shaft
Courtesy of GENERAL MOTORS CORP.

1. Clean the front output shaft in cleaning solvent and air dry.

2. Inspect for spun bearings at the front output shaft bearing areas.

3. Inspect the front output internal splines and driven gear splines for damage or excessive wear.

4. Replace the front output shaft if it is damaged.

5. Inspect the cup plug in the front output shaft for leaking.

6. Replace the cup plug if it is leaking. Refer to Transfer Case Disassemble and Transfer Case

Assemble .

2004 Hummer H2

2004 DRIVELINE/AXLE Transfer Case - Overhaul - BW 4482-NR4

Rear Output Shaft

Fig. 65: View Of Rear Output Shaft Components
Courtesy of GENERAL MOTORS CORP.

1. Clean the rear output shaft with rear output shaft bearing in cleaning solvent.

2. Air dry and ensure all solvent is removed from the bearing.

3. Inspect the speed reluctor wheel for damage.

4. Replace the speed reluctor wheel if it is faulty. Refer to Transfer Case Disassemble and Transfer Case

Assemble .

5. Inspect the rear output shaft bearing for the following conditions:

z

Scoring

z

Pitting

z

Brinelling

z

Excessive wear

6. Replace the rear output shaft bearing if it is faulty. Refer to Transfer Case Disassemble and Transfer

Case Assemble .

7. Inspect the mainshaft rear support bushing for the following conditions:

z

Pitted

z

Wear

z

Corrosion

8. Replace the mainshaft rear support bushing if any of the above conditions are found. Refer to Transfer

Case Disassemble and Transfer Case Assemble .

9. Inspect the rear output shaft splines for wear or damage.

10. Inspect the rear output shaft bearing area for a spun bearing.

11. Replace the rear output shaft if any of the above conditions are found.

Shift System Components

1. Clean the following shift system components in cleaning solvent and air dry.

2004 Hummer H2

2004 DRIVELINE/AXLE Transfer Case - Overhaul - BW 4482-NR4