Hummer H1 (2006+). Manual - part 197

5-28

Transmission/Transfer Case

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NOTE: The pressure control valve retaining bracket must not be modified. Note that the angle between the two bracket surfaces is
less than 90 degrees. Replace the bracket if the angle is 90 degrees or more (Figure 5-11).

Figure 5-10: Solenoid C

Figure 5-11: Pressure Control Valve Retaining Bracket

Installation

Put the new solenoid into position and secure with the clip (Figure 5-12).

Connect the internal wiring harness to the solenoid.

Install the internal filter and the transmission pan.

Fill the transmission with DEXRON

III Automatic Transmission Fluid and follow the fluid checking procedure.

SOLENOID C

RETAINING CLIP

VALVE BODY

PRESSURE CONTROL VALVE

RETANING BRACKET

VALVE

BODY

SPRINGS

ACCUMULATORS

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Transmission/Transfer Case 5-29

5745804

Figure 5-12: Solenoids And Pressure Switch Manifold (PSM)

PRESSURE SWITCH MANIFOLD REPLACEMENT (PSM)

NOTE: Individual pressure switches cannot be replaced. When any pressure switch needs replacing, the entire assembly must be
replaced.

Removal

Remove the oil pan and transmission internal oil filter.

Disconnect the internal wiring harness connector from the PSM.

Remove the two bolts securing the PSM and remove the PSM (Figure 5-12).

SOLENOID C

SOLENOID G

SOLENOID F

SOLENOID D

SOLENOID E

SOLENOID B

SOLENOID A

PRESSURE SWITCH

MANIFOLD

5-30

Transmission/Transfer Case

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Installation

Place the new PSM in position and install one bolt in a recessed location to hold the PSM in position. Start the remaining bolt
in recessed locations and torque the bolts to 108 lb-in (12 N·m) (Figure 5-12).

Connect the internal wiring harness connector to the PSM.

Install the oil pan and transmission internal oil filter.

Refill the transmission with DEXRON III Automatic Transmission Fluid and follow the fluid checking procedure.

TRANSMISSION

Removal

Disconnect the batteries.

Remove the engine cover.

Remove the three bolts securing the down pipe heat shield.

Remove the turbo exhaust down pipe clamp at the turbo.

Remove the two nuts and the bolt securing the transmission dipstick tube.

Remove the upper transmission bell housing bolts.

Remove the drive line protection.

Drain the transmission fluid.

Remove the turbo exhaust down pipe to the rear exhaust camp and remove the exhaust down pipe.

10. Remove the transmission and the transfer case vent lines (Figure 5-13).

11. Remove the rear propeller shaft.

12. Remove the bolts securing the front propeller shaft to the transfer case and position the shaft out of the way.

13. Remove the Transfer case safety cable.

14. Remove the starter.

15. Remove the torque converter bolts.

16. Remove the transmission harness.

17. Remove the transmission cooler lines from the transmission.

18. Clamp the transfer case cooler lines as close to the case as possible with clamp pliers and remove the lines from the case.

19. Remove the P clamp securing the transfer case cooler lines to the adapter plate.

20. Support the transmission and remove the four bolts securing the transmission crossmember.

21. Remove the two nuts securing the crossmember to the transmission mount and remove the transmission crossmember.

22. Remove the two bolts securing the transmission mount to the transfer case adapter plate and remove the mount.

23. Remove the P clamp securing the wiring harness to the transfercase.

24. Remove the transfer case shifter cable from the transfer case shift lever (Figure 5-15).

25. Remove the six nuts securing the transfer case two the transmission and remove the transfercase.

26. Remove the transmission shifter cable from the transmission shift lever (Figure 5-15).

27. Unplug the neutral start back up (NSBU) switch.

28. Unplug the transmission harness from the transmission.

29. Remove the remaining transmission bolts and remove the transmission.

30. Before lowering the transmission install the J-21366 to hold the torque converter into place.

Installation

Install the J-21366 to the converter housing in order to keep the torque converter from sliding off of the turbine shaft.

Raise the transmission into place.

Remove the J-21366.

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Transmission/Transfer Case 5-31

5745804

WARNING: Do not install the transmission by drawing it to the engine using the studs and bolts.

Align the transmission with the engine using the alignment dowels located at the rear of the engine.

NOTE: Make sure that the torque converter can be rotated before tightening the bolts and studs.

Install the converter housing bolts/studs and tighten the bolts/studs to 37 lb-ft (50 N•m).

NOTE: If reusing the torque converter bolts, clean the bolt threads and apply medium strength (blue) thread locker.

Install the torque converter bolts and tighten to 44 lb-ft (60 N•m).

Install the starter, secure with the two bolts and tighten to 58 lb-ft (78 N•m)

Install the transmission fill tube to the converter housing studs and tighten the nuts to 13 lb-ft (18 N•m).

Install the transfer case, secure with the six nuts and tighten to 23 lb-ft. (31 N•m).

10. Install the transmission mount, secure with the two bolts and tighten to 37 lb-ft (50 N•m).

11. Install the transmission crossmember to the transmission mount, secure with the two nuts and tighten to 30 lb-ft. (40 N•m).

12. Secure the transmission crossmember to the frame with the four nuts/bolts and tighten to 90 ft-lb (122 N•m).

13. Plug in the transmission main harness, NSBU switch and all the speed sensors.

14. Install the Transfer case safety cable.

15. Install the rear propeller shaft.

16. Install the front propeller shaft to the transfer case.

17. Install the transmission and the transfer case shift cables (Figure 5-15).

18. Install the transfer case cooler lines and remove the clamp pliers from the lines.

19. Secure the cooler lines to the adapter plate with the P clamp.

20. Install the transmission and the transfer case vent lines (Figure 5-13).

21. Install the exhaust down pipe and the heat shield.

22. Install the drive line protection.

23. Install the engine cover.

24. Connect the batteries.

25. Refill the transmission with DEXRON

III Automatic Transmission Fluid and follow the fluid checking procedure.

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