Hummer H1 (2006+). Manual - part 199

5-36

Transmission/Transfer Case

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TRANSFER CASE LEVER KNOB

Removal

1.

Rotate the shift knob counterclockwise to unscrew the knob from the shift lever.

Installation

1.

Rotate the shift knob clockwise to screw the knob on to the shift lever.

NEUTRAL START BACKUP SWITCH (NSBU) REPLACEMENT

Removal

1.

Set the hand brake and Place the shifter in the neutral (N) position.

NOTE: A new NSBU switch will come in the neutral position. If reinstalling a switch that was previously removed, make sure not
to change the position to ensure proper alignment.

2.

Remove the front propeller shaft at the transfer case and position it out of the way.

3.

Remove the NSBU switch wire connector.

4.

Remove the nut securing the shift lever to the transmission (Figure  5-16).

5.

Remove the two bolts securing the NSBU switch to the transmission and remove the switch (Figure  5-16).

Figure 5-16:   NSBU Switch

Installation

1.

Make sure the shifter is in the Neutral (N) position.

NOTE: If reinstalling the switch that was removed make sure the switch position has not changed.

NOTE: If installing a new switch, the new switch comes pre positioned in neutral and is held into place with a tab that will brake
away when the shifter position is changed. 

2.

Slide the NSBU switch over the manual shift shaft.

3.

While holding the NSBU switch, install the two bolts and tighten the bolts to 20 lb-ft (27 Nm). 

WARNING:  While performing step 4, hold the shift lever with a wrench to keep it from moving. Damage could
occur to the transmission switch if the lever is not held.

4.

Install the nut securing the shift lever to the transmission and tighten to 18 lb-ft (24 N•m).

5.

Install the NSBU switch wire connector.

6.

Install the front propeller shaft at the transfer case.

SHIFT

LEVER

SHIFT

LEVER NUT

NSBU

SWITCH

NSBU

BOLT

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 Transmission/Transfer Case  5-37

5745804

TRANSMISSION MOUNT/ISOLATOR

Removal

1.

Remove the driveline protection.

2.

Support the transmission.

3.

Remove the guide cable retaining nut from the transmission crossmember support bracket bolt.

4.

Remove the transmission crossmember support bracket bolts, nuts and washers from the crossmember (Figure  5-17).

5.

Remove the transmission crossmember support bracket bolts, locknuts and washers from the frame rail and remove the
support brackets.

6.

Remove the two crossmember to transmission mount/isolator locknuts and remove the crossmember.

7.

Remove the two bolts holding the transmission mount/isolator to the transmission and remove the mount/isolator.

Installation

1.

Position the new transmission mount/isolater into place, install and torque the bolts to 35 lb-ft. (47 N•m).

2.

Install the crossmember and the two crossmember-to-transmission mount/isolater locknuts. Tighten the locknuts to 28 lb-ft.
(38 N•m).

3.

Install the transmission crossmember support bracket on the two bolts and the frame rail with the two washers and the
locknuts. Tighten the locknuts to 90 lb-ft. (122 N•m).

4.

Install the transmission mount to crossmember bolts, locknuts and washers. Tighten the locknuts to 90 lb-ft. (122 N•m).

5.

Install the guide cable and the retaining locknut to the transmission crossmember support bracket bolt. Tighten the locknut to
90 lb-ft. (122 N•m).

6.

Install the driveline protection.

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5-38

Transmission/Transfer Case

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Figure 5-17:   Crossmember Removal

RIGHT SIDE

FRAME RAIL

TRANSMISSION 

CROSSMEMBER

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 Transmission/Transfer Case  5-39

5745804

TRANSFER CASE DESCRIPTION

Hummer H1 vehicles are equipped with the New Process Gear, model 242 transfer case. If you have questions about the transfer
case that are not answered by this section, you can call the Transfer Case Hotline at 1-800-945-4327 for more information.

The 242 is a full-time, 4-wheel drive transfer case with three operating ranges plus a neutral position. The operating ranges are
High (H), Low (L), and High Lock (HL). Low range (L) position provides a 2.72:1 reduction ratio for greater low speed, off-road
torque capability.

The transfer case extension, bearing retainer, rear case, and front case are all aluminum castings. The front and rear output drive
sprockets are interconnected by a drive chain (Figure  5-18). A differential in the transfer case, allows the front/rear output shafts to
run at differing speeds. This permits full-time, 4-wheel drive operation in high range. The 242 is also equipped with an internal-
mount oil cooler.

Figure 5-18:   Model 242 Transfer Case

FRONT RETAINER

LOW RANGE PLANETARY

RANGE SLEEVE

MODE

DIFFERENTIAL

DRIVE SPROCKET

SPEEDOMETER

TONE WHEEL

MAINSHAFT

EXTENSION

HOUSING

REAR

RETAINER

DRIVE CHAIN

REAR CASE

DRIVEN SPROCKET

FRONT OUTPUT SHAFT

YOKE

COOLER TUBE

FRONT CASE

ANNULUS

GEAR

INPUT
GEAR

SLEEVE

10-1-08