Hummer H2. Manual — part 898

Fig. 30: Pinion Shaft Lock Bolt
Courtesy of GENERAL MOTORS CORP.

8. Install the pinion shaft lock bolt.

Do not torque the pinion shaft lock bolt at this time.

2004 Hummer H2

2004 DRIVELINE/AXLE Drive Axle - Locking/Limited Slip - Hummer H2

Fig. 31: Measuring Backlash Of Pinion Gear Closest To Pinion Shaft Lock Bolt & Differential Side
Gear
Courtesy of GENERAL MOTORS CORP.

9. Measure the backlash of the pinion gear closest to the pinion shaft lock bolt and the differential side gear

by doing the following:

1. Rotate the pinion gear so that one of the teeth is perpendicular to the ring gear flange.

2. Install a brass drift between the locking differential side gear and the pinion shaft in order to

prevent the side gear from moving.

3. Install the J 7872 (1) to the ring gear flange. See Special Tools and Equipment .

4. Loosely clamp the J 7872-2 (2) and the J 8001-3 (3) onto the stem on the J 7872 (1). See Special

Tools and Equipment .

2004 Hummer H2

2004 DRIVELINE/AXLE Drive Axle - Locking/Limited Slip - Hummer H2

5. Install the J 7872-3 (4) to the J 8001-3 (3).

6. Place the contact pad of the J 7872-3 (4) onto one of the teeth of the pinion gear closest to the

locking differential side gear.

Preload the dial of the J 8001-3 approximately 3/4 of a turn clockwise.

7. Tighten the lock nut of the J 7872-2 (2) finger tight.

8. Turn the dial of the J 8001-3 until the needle and the dial face indicate ZERO.

9. Pull the pinion gear firmly into the differential case seat.

10. Rotate the pinion gear back and forth.

11. Measure the backlash.

Specification: The backlash between the locking differential side gear and the pinion gears should
be 0.051-0.076 mm (0.002-0.003 in).

10. If the backlash is too large, disassemble the differential, install the next larger size side gear thrust

washer, re-assemble the differential and recheck the backlash.

11. If the backlash is too small, disassemble the differential, install next smaller size side gear thrust washer,

re-assemble the differential and recheck the backlash.

Differential side gear thrust washers are available in the following sizes:

Washer Sizes:

z

19.05 mm (0.750 in)

z

20.32 mm (0.800 in)

z

21.59 mm (0.850 in)

z

22.86 mm (0.900 in)

z

24.13 mm (0.950 in)

z

25.40 mm (1.000 in)

z

26.67 mm (1.050 in)

z

27.94 mm (1.100 in)

z

29.21 mm (1.150 in)

z

30.48 mm (1.200 in)

z

31.75 mm (1.250 in)

LOCKING DIFFERENTIAL ASSEMBLE

IMPORTANT:

z

If the same differential side gears and the thrust washers are being used,
install the differential side gears and the thrust washers in their original
locations.

2004 Hummer H2

2004 DRIVELINE/AXLE Drive Axle - Locking/Limited Slip - Hummer H2

1. Measure the backlash of the pinion gears to differential side gear and locking differential side gear. Refer

to Locking Differential Adjustment .

Fig. 32: Locking Differential Side Gear & Thrust Washer
Courtesy of GENERAL MOTORS CORP.

2. Install the differential side gear thrust washer to the locking differential side gear.

3. Install the locking differential side gear and thrust washer into the ring gear side of the differential case.

z

The locking differential side gear and the differential side gear are not
interchangeable. The side gears must be installed in the correct location
in order for the locking differential to function properly.

2004 Hummer H2

2004 DRIVELINE/AXLE Drive Axle - Locking/Limited Slip - Hummer H2