Hummer H2. Manual — part 881

4. If the rotating torque of the drive pinion is less than 1.7 N.m (15 lb in) for new bearings or 1.1 N.m (10 lb

in) for used bearings, tighten the pinion in small increments until the specified rotating torque is obtained.

5. If the rotating torque of the drive pinion is greater than 3.4 N.m (30 lb in) for new bearings or 2.3 N.m

(20 lb in) for used bearings, remove the drive pinion and replace the collapsible spacer and re-install the
drive pinion. Refer to Drive Pinion Bearings Replacement .

6. Install the differential assembly into the axle housing, if necessary.

7. Support the differential assembly in order to prevent the differential assembly from falling out of the axle

housing.

8. Slide the differential case assembly towards the right side axle housing until the ring gear contacts the

drive pinion.

This is the ZERO backlash point.

If the ZERO backlash cannot be obtained, turn the differential bearing adjuster nut into the axle housing
using the J 24429 until the ring gear fully contacts the drive pinion to obtain the ZERO backlash. See
Special Tools and Equipment .

9. While holding the ring gear against the pinion, turn the differential bearing adjuster nut out from the axle

housing using the J 24429 until it contacts the differential side bearing. See Special Tools and
Equipment .

10. Turn the adjuster nut out from the axle housing an additional 2 slots using the J 24429 in order to obtain

the initial backlash adjustment. See Special Tools and Equipment .

IMPORTANT: Do not force the ring gear into contact with the drive pinion.

2004 Hummer H2

2004 DRIVELINE/AXLE Rear Drive Axle - Hummer H2

Fig. 114: Installing J 22779 Into Left Side Axle Housing
Courtesy of GENERAL MOTORS CORP.

11. Install the J 22779 into the left side axle housing between the differential bearing bore and the differential

bearing cup. See Special Tools and Equipment .

12. Tighten the knob of the J 22779 until there is moderate drag when the J 22779 is moved. See Special

Tools and Equipment .

13. Remove the J 22779 . See Special Tools and Equipment .

14. Measure the J 22779 in 3 locations. See Special Tools and Equipment .

15. Calculate the average of the 3 measurements.

The resulting value is the shim thickness required in order to set the initial backlash of the differential
assembly.

16. Select a service shim of approximately the same thickness to install into the axle housing.

IMPORTANT: Over-tightening may spread the axle housing and result in incorrect shim

selection.

2004 Hummer H2

2004 DRIVELINE/AXLE Rear Drive Axle - Hummer H2

Verify the thickness of the service shim using a micrometer.

17. Install the service shim into the axle housing between the differential bearing bore and the differential

bearing cup.

18. Install the left and the right side differential bearing caps.

19. Install the left and the right side differential bearing cap bolts.

Tighten the differential bearing cap bolts finger-tight. Do not torque the bolts at this time.

20. Firmly tighten the differential bearing adjuster nut using the J 24429 in order to force the differential case

assembly into solid contact with the service shim. See Special Tools and Equipment .

21. Rotate the pinion several times in order to seat the bearings.

22. Loosen the differential bearing adjuster nut using the J 24429 until the nut is free from the differential

side bearing. See Special Tools and Equipment .

23. Tighten the differential bearing adjuster nut using the J 24429 until the differential bearing adjuster nut

contacts the bearing. See Special Tools and Equipment .

24. Once the right differential bearing adjuster contacts the differential bearing, tighten the differential

bearing adjuster nut using the J 24429 the following additional amounts:

Tighten:

z

For new bearings, tighten the differential bearing adjuster nut an additional 3 slots.

z

For used bearings, tighten the differential bearing adjuster nut an additional 2 slots.

25. Install the right differential bearing adjuster nut lock.

26. Install the right differential bearing adjuster nut lock bolt.

Do not torque the bolt at this time.

27. Tighten the bearing cap bolts.

Tighten: Tighten the bearing cap bolts to 85 N.m (63 lb ft).

28. Measure the drive pinion and differential case side bearing preload using an inch-pound torque wrench.

Rotate the pinion several times to ensure the bearings have seated.

Specification: The rotating torque of the drive pinion and differential case bearings should be 3.9-6.2
N.m (30-55 lb in) for new bearings or 2.8-5.1 N.m (25-45 lb in) for used bearings.

Record the measurement.

29. Calculate the differential side bearing preload by subtracting the drive pinion preload, measured in Step 2,

NOTE:

Refer to Fastener Notice in Cautions and Notices.

2004 Hummer H2

2004 DRIVELINE/AXLE Rear Drive Axle - Hummer H2

from the drive pinion and differential case bearing preload, measured in Step 35.

Multiply the value obtained by the axle ratio.

Specification: The differential case side bearing preload should be 1.7-4.0 N.m (15-35 lb in).

30. If the differential case side bearing preload is too low, tighten the differential bearing adjuster nut in 1 slot

increments until the specified rotating torque is obtained.

31. If the differential case side bearing preload is too high, loosen the differential bearing adjuster nut in 1

slot increments until the specified rotating torque is obtained.

32. Once the differential side bearing preload is correct, measure the drive pinion to differential assembly

backlash and adjust, if necessary. Refer to Backlash Adjustment .

Differential side bearing shims are available in the following sizes:

Shim Sizes:

z

5.59 mm (0.220 in)

z

5.64 mm (0.222 in)

z

5.69 mm (0.224 in)

z

5.74 mm (0.226 in)

z

5.79 mm (0.228 in)

z

5.84 mm (0.230 in)

z

5.89 mm (0.232 in)

z

5.94 mm (0.234 in)

z

5.99 mm (0.236 in)

z

6.05 mm (0.238 in)

z

6.10 mm (0.240 in)

z

6.15 mm (0.242 in)

z

6.20 mm (0.244 in)

z

6.25 mm (0.246 in)

z

6.30 mm (0.248 in)

z

6.35 mm (0.250 in)

z

6.40 mm (0.252 in)

z

6.45 mm (0.254 in)

z

6.50 mm (0.256 in)

z

6.55 mm (0.258 in)

BACKLASH ADJUSTMENT

Tools Required

2004 Hummer H2

2004 DRIVELINE/AXLE Rear Drive Axle - Hummer H2