Hummer H2. Manual — part 844

Fig. 4: Removing/Installing Axle Shaft Assembly
Courtesy of GENERAL MOTORS CORP.

Installation

1. Wrap shop towels around both the inner and the outer axle shaft boots in order to avoid damage to the

boots during installation.

2.

Insert the axle shaft splined shank into the knuckle hub. Install the washer and the new hub nut to the axle
shaft. DO NOT tighten the new hub nut at this time.

3. Attach the axle shaft inboard flange to the output shaft flange using the inboard flange bolts. See Fig. 4 .

Insert a drift or a large screwdriver through the brake caliper into one of the brake rotor vanes in order to

NOTE:

Clean the steering knuckle and the axle shaft splines and threads. These areas
must be dry and free of grease, dirt, and contamination.

NOTE:

Use only a genuine GM(R) front axle shaft nut. Installation of anything but an
OEM front axle shaft nut could cause damage to the vehicle.

CAUTION: Clean the steering knuckle and the axle shaft splines and threads.

These areas must be dry and free of grease, dirt, and contamination.

2004 Hummer H2

2003-04 DRIVE AXLES Axle Shafts - Front - Hummer H2

prevent the axle shaft from turning. Tighten the inboard flange bolts to specification. See TORQUE
SPECIFICATIONS . Tighten the hub nut to specification.

4. Remove the drift from the rotor. Install the axle shaft center cap, if equipped. Connect the stabilizer shaft

link to the lower control arm.

5. Install the wheel and tire assembly. Tighten wheel lug nuts to specification. Lower the vehicle.

OVERHAUL

INNER JOINT & SEAL

Disassembly

1. Use a hand grinder in order to cut through the swage ring. Remove the tripot housing from the axle shaft.

See Fig. 5 .

2. Wipe the grease off of the housing. Thoroughly degrease the tripot housing. Allow the tripot housing to

dry prior to assembly. Using side cutters, remove the small boot retaining clamp.

3. Remove spacer ring, the tripot spider assembly and the tripot boot from the axle shaft bar. See Fig. 6 .

Clean the axle shaft bar. Use a wire brush in order to remove any rust in the seal mounting area (grooves).

4. Inspect the needle rollers, needle bearings, and trunnion. Inspect the tripot housing for unusual wear,

cracks, or other damage. Replace any damaged parts with the appropriate service kit as necessary.

CAUTION: Use caution when using the hand grinder by the tripot housing.

NOTE:

Required Tools: Axle Shaft Seal Clamp Pliers (J-35910), Axle Shaft Clamp
Swage Tool (J-36652) and Axle Swage Tool (J-36652-98).

2004 Hummer H2

2003-04 DRIVE AXLES Axle Shafts - Front - Hummer H2

Fig. 5: Removing/Installing Tripot Housing Boot
Courtesy of GENERAL MOTORS CORP.

2004 Hummer H2

2003-04 DRIVE AXLES Axle Shafts - Front - Hummer H2

Fig. 6: Identifying Spacer Ring, Tripot Spider Assembly & Tripot Boot
Courtesy of GENERAL MOTORS CORP.

Reassembly

1. Place the new small seal clamp onto the small end of the joint seal. Compress the joint seal and small seal

clamp onto the axle shaft bar. Position the small end of the joint seal into the joint seal groove on the axle
shaft bar. See Fig. 7 .

2. Secure the small seal clamp with Axle Shaft Seal Clamp Pliers, or equivalent, a breaker bar, and a torque

wrench. See Fig. 8 . Tighten the small seal clamp to specifications. See TORQUE SPECIFICATIONS .
Inspect the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Gap
dimension is .085" (2.15 mm).

3. Assemble the tripot joint with the convolute retainer in the correct position, as illustrated. See Fig. 9 .

Install the convolute retainer tool over the inboard joint seal, being sure to capture 2-4 convolutions.

4. Install the tripot spider assembly onto the axle shaft bar. See Fig. 6 . Install the spacer ring in the groove

at the end of the axle shaft bar. Pack the tripot seal and the tripot housing with the grease supplied in the
kit. The amount of grease supplied in this kit has been pre-measured for this application.

2004 Hummer H2

2003-04 DRIVE AXLES Axle Shafts - Front - Hummer H2