Hummer H2. Manual — part 869

Recommendations in Maintenance and Lubrication.

8. Install the drive pinion into the axle housing.

9. Install the outer pinion bearing onto the pinion.

Fig. 73: Installing New Pinion Oil Seal Using J 22388
Courtesy of GENERAL MOTORS CORP.

10. Install a new pinion oil seal using the J 22388 . See Special Tools and Equipment .

11. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion

yoke.

12. Install the pinion yoke.

13. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft

threads show through the yoke.

14. Install the washer and a new pinion nut.

15. Install the J 8614-01 onto the pinion yoke.

NOTE:

Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion
components may be damaged if the pinion flange/yoke is hammered onto
the pinion shaft.

2004 Hummer H2

2004 DRIVELINE/AXLE Rear Drive Axle - Hummer H2

16. Tighten the pinion nut while holding the J 8614-01 .

Tighten: Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the
nut to seat the bearings.

Fig. 74: Measuring Pinion Rotation Torque
Courtesy of GENERAL MOTORS CORP.

17. Measure the rotating torque of the drive pinion using an inch-pound torque wrench.

Specification: The rotating torque of the drive pinion should be 1.7-3.4 N.m (15-30 lb in).

18. If the rotating torque of the drive pinion is less than 1.7 N.m (15 lb in), continue to tighten the pinion nut

until the specified torque is obtained.

Rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust
if necessary.

NOTE:

Refer to Fastener Notice in Cautions and Notices.

IMPORTANT: If the rotating torque is exceeded, the pinion will have to be removed and

a new collapsible spacer installed.

2004 Hummer H2

2004 DRIVELINE/AXLE Rear Drive Axle - Hummer H2

19. If the rotating torque of the drive pinion is greater than 3.4 N.m (30 lb in), remove the drive pinion and

replace the collapsible spacer and re-install the drive pinion following the steps above.

20. Install the differential assembly. Refer to Differential Replacement .

21. Install the brake rotors. Refer to Brake Rotor Replacement - Rear in Disc Brakes.

22. Install the brake calipers. Refer to Brake Caliper Replacement - Rear in Disc Brakes.

23. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and

Wheels.

24. Fill the axle with lubricant. Use the proper fluid. Refer to Lubricant Replacement - Rear Drive Axle .

25. Lower the vehicle.

DIFFERENTIAL REPLACEMENT

Tools Required

z

J 24429 Side Bearing Backlash Spanner. See Special Tools and Equipment .

z

J-38125 Terminal Repair Kit

Removal Procedure

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

2. Remove the tires and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and

Wheels.

3. Remove the brake calipers. Refer to Brake Caliper Replacement - Rear in Disc Brakes.

4. Remove the rear axle housing cover and the gasket. Refer to Rear Axle Housing Cover and Gasket

Replacement .

5. Remove the axle shafts. Refer to Rear Axle Shaft Replacement .

6. Disconnect the electronic locking differential coil harness connector.

IMPORTANT: Group and mark the shims together as originally removed. If you remove or

replace the ring gear and drive pinion, the differential side bearing preload,
backlash, and gear tooth contact pattern check procedures must be performed
in order to ensure proper contact of the gears. If you re-install or replace the
differential assembly without replacing any other component (i.e. drive pinion
and ring gear, differential side bearings, etc.) then you may reinstall the
differential assembly with the original shims in their original locations. Always
perform a gear tooth contact pattern check, even when you remove only the
differential assembly.

2004 Hummer H2

2004 DRIVELINE/AXLE Rear Drive Axle - Hummer H2

Fig. 75: Positive Terminal Lock Reinforcer
Courtesy of GENERAL MOTORS CORP.

7. Remove the positive terminal lock reinforcer using the J 38125-552.

2004 Hummer H2

2004 DRIVELINE/AXLE Rear Drive Axle - Hummer H2