General Body Information - Hummer H1 Service Manual

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10-2 Body
Rear License Plate Bracket Replacement . . . . . . . . . . . . . . . .10-62
Rear Striker Assembly Replacement. . . . . . . . . . . . . . . . . . . .10-61
Rear Support Bow Bracket, Station Wagon . . . . . . . . . . . . . .10-61
Rear Vertical Door
Door Frame and Seal Replacement . . . . . . . . . . . . . . . . .10-77
Door Handle Replacement . . . . . . . . . . . . . . . . . . . . . . . .10-75
Door Latch and Latch Rod Replacement . . . . . . . . . . . .10-75
Door Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-74
Door Stop Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .10-77
Window Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-74
Roadside Emergency Equipment . . . . . . . . . . . . . . . . . . . . . .10-64
Seat Belts
Seat Belt Assembly Replacement . . . . . . . . . . . . . . . . . .10-22
Seats
Front Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-23
Reclining Seat Replacement . . . . . . . . . . . . . . . . . . . . . .10-24
Standard Seat Pedestal Repair . . . . . . . . . . . . . . . . . . . .10-23
Slant Back
Glass and Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-91
Slant Door and Torsion Assembly Replacement . . . . . .10-87
Slant Door Handle, Latch, And Lock Actuator . . . . . . . .10-88
Wiper Motor and Components . . . . . . . . . . . . . . . . . . . . .10-90
Soft Top
Mounting Components and Accessories . . . . . . . . . . . .10-67
Soft Top Support/Roll Cage Assembly . . . . . . . . . . . . . .10-71

GENERAL BODY INFORMATION

1. The HUMMER body is constructed from high strength T6
aluminum. Welding should not be performed to make body
repairs. Heat generated by welding will reverse the temper-
ing process, causing a reduction in material strength.
2. The hood and engine access covers are made of fiberglass
(sheet molding compound). Cracks, splits, or holes may be
repaired with a glass-reinforced plastic laminate.
3. Solid 0.1875 in. (4.8 mm) diameter aluminum rivets are
the primary method of joining body components. Each
rivet is inserted into a hole through two pieces of metal,
and a second head is formed by manual or pneumatic
impacting, or by squeezing the rivet. When making
repairs, use blind rivets of the same size, or oversize, with
the appropriate grip length.
4. Blind structural aluminum rivets of 0.1875 in. (4.8 mm)
diameter are used in applications where there is access
from only one side of the part. Blind rivets are installed
using a tool that pulls on the rivet stem causing a bulbed
head to form on the back side of the part. Fastening is
complete when stem breaks off. High strength is obtained
in blind rivets by mechanically locking the remaining stem
inside the rivet body.
4-1-00
Speedometer/Odometer Replacement . . . . . . . . . . . . . . . . . . 10-17
Splash Shield (Engine) Replacement . . . . . . . . . . . . . . . . . . . 10-52
Tachometer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
Tailgate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72
Chain Brackets Replacement . . . . . . . . . . . . . . . . . . . . . 10-72
Chain Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-73
Tailgate and Seals Replacement . . . . . . . . . . . . . . . . . . . 10-72
Tire Jack
Jack and Triangle Warning Kit
Hold-Down Bracket Replacement . . . . . . . . . . . . . . . . 10-64
Visor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
Water Leak Detection and Repair . . . . . . . . . . . . . . . . . . . . . . 10-12
Windshield
Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54
Glass and Weatherstrip Replacement . . . . . . . . . . . . . . 10-53
Heated Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55
Reservoir and Pump Assembly . . . . . . . . . . . . . . . . . . . . 10-58
Washer Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . 10-58
Washer Nozzle Replacement . . . . . . . . . . . . . . . . . . . . . . 10-58
Washer System and Components . . . . . . . . . . . . . . . . . 10-58
Windshield Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53
Wiper Jumper Harness Replacement . . . . . . . . . . . . . . . 10-58
Wiper Linkage Replacement . . . . . . . . . . . . . . . . . . . . . . 10-57
Wiper Motor Assembly Replacement . . . . . . . . . . . . . . . 10-56
Wiper Pivot Replacement . . . . . . . . . . . . . . . . . . . . . . . . 10-57
Wiper System and Components . . . . . . . . . . . . . . . . . . . 10-56
5. Steel pull-type lockbolt fasteners of 0.1875 in. (4.8 mm)
and 0.25 in. (6.4 mm) diameters are used where tension or
high-shear loads exist.
unthreaded fasteners. One part is a high-strength, steel-
headed, bolt-like part with serrations on its shank. The
mating part is a collar which is swagged over the
serrations causing the fastener to be locked in place.
6. To facilitate body repairs, it is acceptable to replace
lockbolt fasteners and rivets with 0.25 in. (6.4 mm) series
bolts. Do not replace lockbolt fasteners with rivets.
Standard threaded fasteners should not be used, as these
will quickly wear the aluminum structure. Bolt lengths
should be chosen so that the cylinder portion of bolt is
bearing on all members being joined. Bolts are designed as
AN4-XX or AN4-C-XX, where XX defines grip length.
Tighten all bolts to 71 lb in. (8 N•m).
7. Fatigue strength of riveted joints and seams is increased
by epoxy adhesive application. Epoxy adhesive requires
special material storage and metal preparation along with a
low temperature heat cycle for curing. Where possible,
extra rivets and thicker metal gauges should be used
instead of adhesives when making repairs. Parts may be
difficult to separate, even after rivets are removed.
Lockbolts are two-piece
®