Hummer H2. Manual — part 2719

7. Replace the front case half if any of the above conditions are found.

8. Inspect the sealing surfaces (1) for damage.

9. Repair small scratches or nicks with a soft stone.

10. Inspect the front case to transmission case mounting surface for damage.

11. Inspect the case threaded bolt holes (2) for damage.

12. Repair any damaged threads.

13. Inspect the transmission to transfer case studs for damage.

14. Replace any damaged studs. Refer to Transfer Case Disassemble and Transfer Case Assemble .

15. Inspect the location pins (3) for being loose or missing.

16. Repair or replace any damaged location pins.

17. Inspect the front output shaft front bearing and the input shaft bearing for the following conditions:

z

Roughness

z

Brinelling

z

Pitting

18. Replace the bearings if any of the above conditions are found. Refer to Transfer Case Disassemble and

Transfer Case Assemble .

Rear Case Half

1. Clean the rear case half in cleaning solvent and air dry.

2004 Hummer H2

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

Fig. 54: Locating Rear Case Half Inspection Points
Courtesy of GENERAL MOTORS CORP.

2. Remove the sealer from the case sealing surfaces.

3. Inspect the case for being broken or cracked.

4. Replace the case if it is broken or cracked.

5. Inspect the sealing surfaces (1) for damage.

6. Repair small scratches or nicks with a soft stone.

7. Inspect the case threaded bolt holes for damage.

NOTE:

Refer to Machined Surface Damage Notice in Cautions and Notices.

2004 Hummer H2

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

8. Repair any damaged threads.

9. Inspect the front output shaft rear bearing bore (2) for the following conditions:

z

Spun bearing

z

Cracks

10. Inspect the rear output shaft rear bearing bore (5) for the following conditions:

z

Spun bearing

z

Cracks

11. Replace the case if the bearing has spun. Refer to Transfer Case Disassemble and Transfer Case

Assemble .

12. Inspect the retaining ring (6) for the rear output shaft rear bearing for being bent or twisted.

13. Replace a faulty retaining ring.

14. Inspect the rear output shaft bushing (4) for scoring or wear.

15. Replace the case if the rear output shaft bushing is faulty. Refer to Transfer Case Disassemble and

Transfer Case Assemble .

16. Inspect the shift detent lever shaft bore (3) for the following conditions:

z

Out of round

z

Excessive wear

17. Replace the case if the shift detent lever shaft bore is faulty. Refer to Transfer Case Disassemble and

Transfer Case Assemble .

Oil Pump

Fig. 55: Locating Oil Pump Hose & Screen
Courtesy of GENERAL MOTORS CORP.

2004 Hummer H2

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

1. Remove the oil pump suction hose from the oil pump screen.

2. Clean the hose and screen in cleaning solvent and air dry.

3. If the screen is embedded with debris, replace the screen.

4. Inspect the hose for cracking or tears.

5. Replace the hose if it is faulty.

6. Inspect the oil pump for free movement.

7. Replace the oil pump if there is any binding. Do not disassemble the oil pump. The oil pump is serviced

as a unit.

8. Inspect the wear clip on the oil pump.

9. Replace the oil pump if the wear clip is missing or faulty.

High/Low Range Components

Fig. 56: Annulus Gear
Courtesy of GENERAL MOTORS CORP.

1. Clean the annulus gear in cleaning solvent and air dry.

2. Inspect the annulus gear teeth for the following conditions:

z

Damage or excessive wear

2004 Hummer H2

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