Hummer H1 (2006+). Manual - part 209

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Transmission/Transfer Case

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Figure 5-87:   Installing Differential On Mainshaft

15. Install the mode sleeve in the mode fork. Replace the fork pads if worn or cracked. Do not reuse worn pads (Figure  5-91).

16. Install the assembled mode fork and the sleeve on the mainshaft. Then seat the sleeve in the differential  (Figure  5-92).

17. Install the assembled mainshaft, differential, mode fork and sleeve. Be sure the mainshaft is seated in the input gear pilot

bearing, and that the mode fork pin is seated in the upper slot of the shift sector as shown (Figure  5-95).

Figure 5-88:   Differential Snap Ring Installation

DIFFERENTIAL

MAINSHAFT

DIFFERENTIAL

SNAP RING

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 Transmission/Transfer Case  5-77

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Figure 5-89:   Intermediate Clutch Shaft Installation

Figure 5-90:   Intermediate Clutch Shaft Thrust Ring and Snap Ring Installation

18. Install the shift rail. Install the rail through the mode fork, range fork and into the case bore, and install the lock pin

(Figure 5-96).

DIFFERENTIAL

MAINSHAFT

INTERMEDIATE

CLUTCH SHAFT

CLUTCH SHAFT

THRUST RING

INTERMEDIATE

CLUTCH SHAFT

CLUTCH SHAFT

SNAP RING

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Transmission/Transfer Case

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Figure 5-91:   Installing Mode Sleeve in Mode Fork

Figure 5-92:   Mode Fork and Sleeve Installation

19. Install the detent plunger, spring and the plug. Replace the O-ring on the plug, and tighten the plug to 12-18 lb-ft (16-24

N•m)(Figure 5-97).

20. Install the range lever on the sector shaft, then secure the lever with the washer and the nut (Figure  5-97). Tighten the nut to

20-25 lb-ft (27-34 N•m).

21. Install the shift sector shaft O-ring, and the nylon bushing. Use a thin wall socket to seat the O-ring and the bushing.

22. Install the support bracket onto the oil cooler, then install the sealing washers. Set the oil cooler into the transfer case front

half, and install the external hardware. Hand tighten only (Figure  5-93).

23. Align the upper support tab in the recess of the case, and ensure that the lower tab with the extra rivet installed rests on the

recessed casting. The lower tab is designed to have the rivet compressed between the recessed casting area of the front and the
rear transfer case halves when the halves are bolted together. Make sure that the tabs do not intrude into the machined mating
surface area of the transfer case halves. Do not bend the cooler when moving into position, damage to the manifold area could
occur from induced stress.While gently holding the cooler with a 3/4" wrench on the manifold, tighten the hardware to 15 lb-ft
(Figure 5-94).

NOTE: If the cooler is tightened incorrectly, the tension placed on the cooler assembly could cause cracking, leaking and loss of
transmission fluid into the transfer case assembly.

MODE FORK

ASSEMBLY

FORK
PADS

MODE

SLEEVE

DIFFERENTIAL

MAINSHAFT

MODE

SLEEVE

MODE FORK

ASSEMBLY

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Figure 5-93:   Transfer Case Cooler Support Bracket Installation

Figure 5-94:   Transfer Case Cooler Support Tabs 

COOLER SUPPORT
BRACKET

COOLER SEALING
WASHERS

TRANSFER CASE
OIL COOLER

TRANSFER CASE

FRONT HALF

MANIFOLD

CASE HALF

RECESS

 

HOLD WHEN
TIGHTENING

HARDWARE

UPPER COOLER

SUPPORT TAB

TIGHTEN

FIRST

LOWER

SUPPORT

TAB

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