Hummer H1 Service Manual page 354

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FRONT OUTPUT SHAFT SEAL REPLACEMENT
1. Mark front propeller shaft and transfer case yoke for align-
ment reference.
2. Disconnect front propeller shaft at yoke. Retain U-bolts
and nuts (Figure 5-76).
3. Remove yoke nut (Figure 5-77).
4. Remove yoke and seal washer. Use tool J–8614-01 to
remove yoke if necessary.
5. Remove seal from front case bore with standard hook type
seal puller.
6. Coat outer edge of new seal with thin coat of RTV type
sealer.
7. Lubricate seal lip with transmission fluid and install seal
with tool J–38869.
CAUTION: The seal can be installed incorrectly. Be sure the
seal lip is toward the case interior.
8. Smooth seal contact surface of yoke with 320-400 grit
emery coated with transmission fluid. Then clean and
install yoke.
9. Install yoke seal washer.
10. Install and tighten yoke nut to 90-130 lb-ft (122-176 N•m)
torque.
11. Connect propeller shaft to yoke. Tighten U-bolt nuts to 13-
18 lb-ft (18-24 N•m) torque.
12. Check and top off transfer case fluid level if necessary.
FRONT
PROPELLER
SHAFT
Figure 5-76: Disconnecting/Connecting Front
Propeller Shaft
05745159
YOKE
U-BOLT
Transmission/Transfer Case
SEAL
YOKE
WASHER
YOKE
NUT
OIL SEAL
Figure 5-77: Front Output Shaft Yoke and Seal
Removal/Installation
TRANSFER CASE FLUID CHANGE
The transfer case fill and drain plugs are both located in the
rear case (Figure 5-78).
Correct fill level is to the lower edge of the fill plug hole. Rec-
ommended fluid is Dexron III.
1. Place vehicle on level surface. Or, if vehicle is raised on
hoist for fluid change, a drive-on hoist is preferred. Vehicle
must be level for accurate refill fluid level.
2. Remove drain and fill plugs and drain fluid into approved
container.
3. Install and tighten drain plug to 15-25 lb-ft (20-33 N•m)
torque.
4. Refill transfer case with Dexron III. Correct level is to
lower edge of fill plug hole.
5. Install and tighten fill plug to 15-25 lb-ft (20-33 N•m)
torque.
6. Lower vehicle, if on hoist.
Figure 5-78: Transfer Case Drain and Fill Plug
Locations
5-155
FILL
PLUG
DRAIN
PLUG