Hummer H1 Service Manual page 355

5-156 Transmission/Transfer Case
TRANSFER CASE REMOVAL
1. Remove drain plug and drain oil from transfer case. Rein-
stall drain plug afterward.
2. Disconnect propeller shafts from transfer case.
3. Disconnect wiring harness connectors from vehicle speed
sensors range switch, and lock switch.
4. Remove wiring harness clamp and move harness away
from transfer case.
5. Disconnect vent line from transfer case (Figure 5-72).
6. Disconnect cooler hoses at transfer case (Figure 5-79).
7. Disconnect shift rod at range lever (Figure 5-80).
8. Remove guide cable and bracket (Figure 5-80).
COOLER
HOSES
Figure 5-79: Cooler Hose Connections
9. Support transfer case with jack. Secure transfer case to
jack with chain.
10. Remove nuts attaching transfer case to transmission
adapter (Figure 5-81).
FLAT
WASHERS
WAVY
WASHER
RANGE
LEVER
Figure 5-80: Shift Rod Attachment
___________________________________________
TRANSFER CASE
EXHAUST
BRACKET
GUIDE
CABLE AND
BRACKET
SHIFT ROD
Figure 5-81: Separating Transfer Case From
Transmission
11. Slide transfer case rearward and remove it from under
vehicle (Figure 5-81).
TRANSFER CASE INSTALLATION
1. Mount transfer case on jack and secure with chain.
2. Apply bead of Loctite 518 to mounting surface of
transmission adapter.
3. Align and install transfer case on transmission. Tighten
transfer case attaching nuts to 37 lb-ft (50 N•m).
4. Remove jack.
5. Connect shift rod to range lever with washer and cotter pin
(Figure 5-80).
6. Install guide cable and bracket.
7. Connect transfer case vent line.
8. Connect cooler hoses to transfer case cooler fittings.
9. Connect front and rear propeller shafts to transfer case.
Tighten front shaft U-bolt nuts to 13-18 lb-ft (18-24 N•m)
torque.
10. Install vehicle speed sensor.
11. Install range and lock indicator switches.
12. Attach harness clamp to transfer case.
13. Connect wiring harness connectors to speed sensor and
switches.
14. Fill transfer case to bottom edge of fill plug hole with
Dexron III.
15. Check and adjust shift rod if necessary.
TRANSMISSION
ADAPTER
TRANSFER CASE
®