Hummer H1 Service Manual page 364

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Transmission/Transfer Case 5-165
®
TRANSFER CASE CLEANING AND
MAINSHAFT GEAR
INSPECTION
Clean the transfer case components thoroughly with standard
parts cleaning solvent. Remove all traces of sealer from the
case and retainer sealing surfaces.
SPROCKET GEAR
Clean the oil pickup screen with solvent and dry it with com-
pressed air. Also use compressed air to remove solvent residue
from all oil feed passages and channels.
Geartrain
The differential pinion gears and thrust washers are serviceable
components and can be replaced if worn or damaged. The dif-
ferential cases are also serviceable but must be replaced as a set
if either case is damaged.
Inspect the mainshaft splines, gear teeth and bearing surfaces
carefully for evidence of wear, or damage. Replace the shaft if
necessary. Do not attempt to salvage it if damaged.
The range and mode forks are serviced as assemblies. Replace
Figure 5-114: Mainshaft and Sprocket Gear
either part if damaged. However, the nylon pads in the forks
Removal
can be replaced if worn, or cracked.
Inspect the transfer case snap rings closely. Do not attempt to
FRONT CASE
salvage a distorted snap ring by straightening or reshaping it.
PRY TOOL
Replace any snap ring that is distorted, or worn.
Inspect the low range planetary, input gear and thrust washer,
retainer, and snap ring. The low range planetary is serviced as
an assembly only. Replace it if the case or pinions are dam-
aged.
During inspection, also make sure the seal surface of the input
gear is in good condition. Minor nicks on this surface can be
reduced with crocus cloth. However, replace the gear if the seal
surface is severely scored or worn.
SHAFT
Check condition of the low range annulus gear (Figure 5-116).
SEAL
Replace the front case and gear as an assembly if the gear is
damaged. The annulus gear is not serviced separately.
Figure 5-115: Removing Front Output Shaft Seal
The speedometer tone wheel should be replaced if worn,
cracked, or spline teeth are worn.
Inspect the differential gears, thrust washers and case halves.
Replace the mainshaft gear if the gear teeth or the brass ring on
the underside of the gear are damaged. Replace the differential
as an assembly if the gears, case halves, or the pins in the lower
case half are damaged.
Inspect the case halves, extension housing, and both retainers
for cracks, porosity, or damaged sealing surfaces. Inspect the
shafts, gears, chain and shift components for wear or damage.
Inspect all of the transfer case bearings for wear, roughness,
pitting, or galling. Replace worn or damaged bearings.
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