Hummer H1 (2002+). Manual - part 157

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 Axles, Suspension, and Frame  9-89

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05745159

SPECIAL TOOLS

Procure from Kent-Moore.

J–22610

J–3409-01

PART OF 

J–3409-01

J–21787

J–8611-01

J–8608

J–21786

J–24385-01

J–39524

J–33142

J–35237

J–29162

TOOL

DESCRIPTION

J–33142

Axle Shaft and Seal Installer

J–21786

Pinion Rear Bearing Cup Remover

J–21787

Pinion Front Bearing Cup Remover

J–8611-01

Rear Pinion Bearing Race Installer

J–29162

Rear Retaining Seal Installer

J–8608

Rear Pinion Bearing Race Installer

J–39524

Pinion Depth Gauge Set

J–24385-01

Axle Housing Spreader

J–35237

Bearing Installer

J–3409-01

Stand, with Holding Fixtures

Part of J–3409-01

Axle Holding Fixture Adapter

J–22610

Keystone Clamp Pliers

9-90

Axles, Suspension, and Frame

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THIS PAGE INTENTIONALLY BLANK.

 

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 10-1

 

 

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05745159

 

Section 10    Body

 

TABLE OF CONTENTS

 

Airlift to Hood Seal Replacement . . . . . . . . . . . . . . . . . . . . . . .10-51
Armrest Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-24
Ashtray Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20
Body Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3

Aluminum Repair   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-8
Fiberglass Repair   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11
Lockbolt Failure   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-4
Rivet Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3
Rivet Replacement   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-4

Body Mount Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-61
Cargo Tiedown Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .10-72
Center Console Replacement  . . . . . . . . . . . . . . . . . . . . . . . . .10-13
Cigarette Lighter Replacement  . . . . . . . . . . . . . . . . . . . . . . . .10-19
Dimmer Control Switch Replacement . . . . . . . . . . . . . . . . . . .10-17
Door Glass

“Wind Noise”  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-43
Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-41

Door Stop Strap Assembly Replacement . . . . . . . . . . . . . . . .10-41
Doors

Disassembly, Replacement and Repair   . . . . . . . . . . . . .10-36
Door Glass  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-41
Door Seals Replacement   . . . . . . . . . . . . . . . . . . . . . . . . .10-41
Rear Vertical Door Replacement  . . . . . . . . . . . . . . . . . . .10-74

Engine Access Cover  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20

Hold-Down Striker Replacement  . . . . . . . . . . . . . . . . . . .10-20
Inner Flexible Latch Replacement  . . . . . . . . . . . . . . . . . .10-20

Engine Access Cover Maintenance . . . . . . . . . . . . . . . . . . . . .10-20
Former Assembly Replacement, “A” Pillar . . . . . . . . . . . . . . .10-60
Front Console Replacement   . . . . . . . . . . . . . . . . . . . . . . . . . .10-13
Front License Plate Bracket Replacement  . . . . . . . . . . . . . . .10-62
Front Striker Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-61
Fuel Filler Housing Replacement   . . . . . . . . . . . . . . . . . . . . . .10-63
General Body Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2
Glovebox Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-19
Hood

Center Hood Stop Replacement   . . . . . . . . . . . . . . . . . . .10-49
Front Hood Screen Replacement   . . . . . . . . . . . . . . . . . .10-50
Grille and Screen Replacement  . . . . . . . . . . . . . . . . . . . .10-49
Guide Bracket Assembly Replacement   . . . . . . . . . . . . .10-50
Hood and Hinge Replacement  . . . . . . . . . . . . . . . . . . . . .10-47
Hood Latch And Prop Rod  . . . . . . . . . . . . . . . . . . . . . . . .10-43
Hood Prop Rod and Bracket Replacement . . . . . . . . . . .10-45
Hood Release Cable Replacement   . . . . . . . . . . . . . . . . .10-44
Hood Retainer Bracket, L  . . . . . . . . . . . . . . . . . . . . . . . . .10-50
Hood Retainer Bracket, R . . . . . . . . . . . . . . . . . . . . . . . . .10-50
Latch and Bracket Replacement  . . . . . . . . . . . . . . . . . . .10-43
Outer Hood Seal Replacement . . . . . . . . . . . . . . . . . . . . .10-48
Right Close-Out Seal and Retainer  . . . . . . . . . . . . . . . . .10-51
Side Hood Stop Replacement   . . . . . . . . . . . . . . . . . . . . .10-49

Horn

Horn Assembly Replacement  . . . . . . . . . . . . . . . . . . . . . 10-53
Mounting Bracket Replacement  . . . . . . . . . . . . . . . . . . . 10-53

Instrument Panel

Dashpad Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Gauge Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Gauges and Switches   . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Indicator Lamp Replacement   . . . . . . . . . . . . . . . . . . . . . 10-16
Instrument Panel Replacement  . . . . . . . . . . . . . . . . . . . . 10-14
Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17

Interior Trim

B-Bar Replacement   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Driver’s Compartment Trim Replacement  . . . . . . . . . . . 10-28
Floor Carpeting and Padding Replacement . . . . . . . . . . 10-34
Inner Kick Panels Replacement   . . . . . . . . . . . . . . . . . . . 10-32
Outer Kick Panel Replacement  . . . . . . . . . . . . . . . . . . . . 10-33
Passenger’s Compartment Trim  . . . . . . . . . . . . . . . . . . . 10-26
Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Station Wagon Rear Compartment Trim   . . . . . . . . . . . . 10-30
Four-Passenger Soft Top . . . . . . . . . . . . . . . . . . . . . . . . . 10-65

License Plate Brackets   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
Lift Gate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-74
Lights

Backup Light Switch Replacement . . . . . . . . . . . . . . . . . 10-86
Front Courtesy Light   . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-85
Interior and Exterior Lighting   . . . . . . . . . . . . . . . . . . . . . 10-78

Backup Light Switch  . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
Cargo Light   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82
Courtesy Light  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
Domelight Replacement  . . . . . . . . . . . . . . . . . . . . . . . 10-82
Front Turn Signal Light Replacement  . . . . . . . . . . . . 10-80
Identification Light Replacement  . . . . . . . . . . . . . . . . 10-79
Maplight Replacement   . . . . . . . . . . . . . . . . . . . . . . . . 10-83
Optional Trouble Light Replacement . . . . . . . . . . . . . 10-84
Rear Turn Signal Light Replacement . . . . . . . . . . . . . 10-81
Service Headlight Assembly   . . . . . . . . . . . . . . . . . . . 10-78
Service Headlight Electrical Connector and
  Grommet  Replacement   . . . . . . . . . . . . . . . . . . . . . . 10-85
Side Marker Light Assembly   . . . . . . . . . . . . . . . . . . . 10-79
Side Marker Light Lens and Lamp  . . . . . . . . . . . . . . . 10-79
Underhood Light Replacement   . . . . . . . . . . . . . . . . . 10-84

Rear Seat Courtesy Light . . . . . . . . . . . . . . . . . . . . . . . . . 10-83
Stoplight Switch Replacement   . . . . . . . . . . . . . . . . . . . . 10-86

Load Barrier and Mounting Brackets  . . . . . . . . . . . . . . . . . . . 10-25
Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35

Lighted Visor Mirror Replacement  . . . . . . . . . . . . . . . . . 10-84
Power Mirrors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
Rearview Mirror Replacement  . . . . . . . . . . . . . . . . . . . . . 10-36
Side Mirror Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . 10-35

 

10-2

Body

 

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Rear License Plate Bracket Replacement . . . . . . . . . . . . . . . .10-62
Rear Striker Assembly Replacement. . . . . . . . . . . . . . . . . . . .10-61
Rear Support Bow Bracket, Station Wagon  . . . . . . . . . . . . . .10-61
Rear Vertical Door

Door Frame and Seal Replacement . . . . . . . . . . . . . . . . .10-77
Door Handle Replacement  . . . . . . . . . . . . . . . . . . . . . . . .10-75
Door Latch and Latch Rod Replacement  . . . . . . . . . . . .10-75
Door Replacement   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-74
Door Stop Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . .10-77
Window Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-74

Roadside Emergency Equipment  . . . . . . . . . . . . . . . . . . . . . .10-64
Seat Belts

Seat Belt Assembly Replacement  . . . . . . . . . . . . . . . . . .10-22

Seats

Front Seats   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-23
Reclining Seat Replacement  . . . . . . . . . . . . . . . . . . . . . .10-24
Standard Seat Pedestal Repair  . . . . . . . . . . . . . . . . . . . .10-23

Slant Back

Glass and Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-91
Slant Door and Torsion Assembly Replacement . . . . . .10-87
Slant Door Handle, Latch, And Lock Actuator  . . . . . . . .10-88
Wiper Motor and Components . . . . . . . . . . . . . . . . . . . . .10-90

Soft Top

Mounting Components and Accessories  . . . . . . . . . . . .10-67
Soft Top Support/Roll Cage Assembly  . . . . . . . . . . . . . .10-71

Speedometer/Odometer Replacement  . . . . . . . . . . . . . . . . . . 10-17
Splash Shield (Engine) Replacement . . . . . . . . . . . . . . . . . . . 10-52
Tachometer Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
Tailgate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72

Chain Brackets Replacement   . . . . . . . . . . . . . . . . . . . . . 10-72
Chain Replacement   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-73
Tailgate and Seals Replacement . . . . . . . . . . . . . . . . . . . 10-72

Tire Jack

Jack and Triangle Warning Kit

Hold-Down Bracket Replacement . . . . . . . . . . . . . . . . 10-64

Visor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
Water Leak Detection and Repair  . . . . . . . . . . . . . . . . . . . . . . 10-12
Windshield

Assembly Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54
Glass and Weatherstrip Replacement   . . . . . . . . . . . . . . 10-53
Heated Windshield  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55
Reservoir and Pump Assembly . . . . . . . . . . . . . . . . . . . . 10-58
Washer Hoses Replacement  . . . . . . . . . . . . . . . . . . . . . . 10-58
Washer Nozzle Replacement . . . . . . . . . . . . . . . . . . . . . . 10-58
Washer System and Components   . . . . . . . . . . . . . . . . . 10-58
Windshield Assembly   . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53
Wiper Jumper Harness Replacement  . . . . . . . . . . . . . . . 10-58
Wiper Linkage Replacement  . . . . . . . . . . . . . . . . . . . . . . 10-57
Wiper Motor Assembly Replacement  . . . . . . . . . . . . . . . 10-56
Wiper Pivot Replacement   . . . . . . . . . . . . . . . . . . . . . . . . 10-57
Wiper System and Components  . . . . . . . . . . . . . . . . . . . 10-56

 

GENERAL BODY INFORMATION

 

1.

The

 

 

 

HUMMER body is constructed from high strength T6 

aluminum. Welding should not be performed to make body 
repairs. Heat generated by welding will reverse the temper-
ing process, causing a reduction in material strength.

2.

The hood and engine access covers are made of fiberglass
(sheet molding compound). Cracks, splits, or holes may be
repaired with a glass-reinforced plastic laminate.

3.

Solid 0.1875 in. (4.8 mm) diameter aluminum rivets are
the primary method of joining body components. Each
rivet is inserted into a hole through two pieces of metal,
and a second head is formed by manual or pneumatic
impacting, or by squeezing the rivet. When making
repairs, use blind rivets of the same size, or oversize, with
the appropriate grip length.

4.

Blind structural aluminum rivets of 0.1875 in. (4.8 mm)
diameter are used in applications where there is access
from only one side of the part. Blind rivets are installed
using a tool that pulls on the rivet stem causing a bulbed
head to form on the back side of the part. Fastening is
complete when stem breaks off. High strength is obtained
in blind rivets by mechanically locking the remaining stem
inside the rivet body.

5.

Steel pull-type lockbolt fasteners of 0.1875 in. (4.8 mm)
and 0.25 in. (6.4 mm) diameters are used where tension or
high-shear loads exist. Lockbolts are two-piece
unthreaded fasteners. One part is a high-strength, steel-
headed, bolt-like part with serrations on its shank. The
mating part is a collar which is swagged over the
serrations causing the fastener to be locked in place.

6.

To facilitate body repairs, it is acceptable to replace
lockbolt fasteners and rivets with 0.25 in. (6.4 mm) series
bolts. Do not replace lockbolt fasteners with rivets.
Standard threaded fasteners should not be used, as these
will quickly wear the aluminum structure. Bolt lengths
should be chosen so that the cylinder portion of bolt is
bearing on all members being joined. Bolts are designed as
AN4-XX or AN4-C-XX, where XX defines grip length.
Tighten all bolts to 71 lb in. (8 N•m).

7.

Fatigue strength of riveted joints and seams is increased
by epoxy adhesive application. Epoxy adhesive requires
special material storage and metal preparation along with a
low temperature heat cycle for curing. Where possible,
extra rivets and thicker metal gauges should be used
instead of adhesives when making repairs. Parts may be
difficult to separate, even after rivets are removed.

 

4-1-00