Hummer H2. Manual — part 2768

Fig. 113: Identifying Transfer Case Retaining Bolts
Courtesy of GENERAL MOTORS CORP.

NOTE:

This component is made of magnesium. Proper assembly is required to
prevent damage. Ensure the magnesium transfer case housings are
properly insulated from all external steel components, or galvanic
corrosion will occur. New nylon coated case bolts and aluminum washers
must be used. Use only aluminum fill and drain plugs. Use only aluminum
brackets under the case bolts. Ensure new seals are installed that have a

2004 Hummer H2

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

56. Inspect the nylon coating on the case bolts for cuts or tears.

57. Replace the case bolts if there is any damage to the nylon coating.

58. Install the case bolts with washers, and the brackets.

Tighten: Tighten the case bolts to 21 N.m (15 lb ft).

rubber insulated outside diameter and have no tears or cuts. Extensive
damage will occur if there is galvanic corrosion between the magnesium
and steel components.

IMPORTANT: The case bolts are self-tapping; they must be hand started. Do not use

power assisted tools to install the bolts.

2004 Hummer H2

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

Fig. 114: Locating Vehicle Speed Sensor (VSS)
Courtesy of GENERAL MOTORS CORP.

59. Install the vehicle speed sensor (VSS) with a new O-ring seal.

Tighten: Tighten the speed sensor to 17 N.m (13 lb ft).

2004 Hummer H2

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

Fig. 115: Identifying Encoder Motor Assembly
Courtesy of GENERAL MOTORS CORP.

60. Apply a 3.175 mm (1/8 in) bead of RTV sealant GM P/N 12345739 (Canadian P/N 10953541), or

equivalent, to the sealing surface of the encoder motor assembly.

61. Install the encoder motor assembly. Rotate the shift detent lever to align to the encoder motor.

62. Loosely install the encoder motor mounting bolts.

63. Loosely install the encoder motor bracket bolt.

2004 Hummer H2

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