Инструкцию для телефона hummer h1
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Remove filler tube housing bolts. Remove console and engine cover. Для того, чтобы облегчить поиск необходимого руководства пользователя, зная только название модели, предлагаем воспользоваться. Remove four bolts, washers, and steering arm cover from geared hub Figure 9-25. Интересно то, что аккумуляторный отсек закреплен не защелками, как мы привыкли, а двумя надежными болтами. CAUTION: Some connectors can be installed incorrectly and CONNECTOR cause damage to the electrical system. Draw off sample at drain plug. LOAD BEARING BALLS INTO THIS BALL GUIDE PORT INSTALLER WORMSHAFT TOOL FLANGE J—6219 RACK PISTON GEAR Figure 8-53: Rack Piston Loading Port HOUSING For Bearing Balls Figure 8-51: Pitman Shaft Seal Installation... OF RIVET PREFERABLY ABOUT Material 3X THICKNESS OF THICKER SHEET Aluminum material used for repairs should be of the same al- loy and temper as the original if possible. This label is affixed to the air cleaner housing Figure 1-1.
This service manual contains instructions for maintaining the commercial HUMMER. Spend some time looking through this manual. Features to improve the usefulness of this manual and increase your efficiency are: Accessing Information - These include: tabulated sections for quick reference, extensive troubleshooting guides for specific systems, and step-by-step directions for service repairs. This label is affixed to the air cleaner housing Figure 1-1. Figure 1-1: Emission Control Information Label Information 05745159... For more information on the GVWR and GAWR, refer to ÒVEHICLE LOADING INFORMATIONÓ in the Hummer OwnerÕs Manual. Figure 1-3: Safety Certification Label for 10,300 lb GVWR Vehicles Figure 1-4: Safety Certification Label for... The label is re- quired by the EPA and includes a tamper-proof feature. Four Cycle, Turbocharged Diesel, Liquid-Cooled Power Output:..................... Torque 1800 rpm Engine Dimensions: Length.................................... R-134a Capacity system + 2 oz. Electric Drive, Thermal Cutoff Switch Capacity................................. Goodyear Tire Size 37 in. Antilock Brake System lhÊ... BOLT SAE GRADE SAE GRADE SAE GRADE SAE GRADE SIZE NO. Seating materials are available in cloth and vinyl. Soft top colors and codes are: Tan T and Black B. Exterior paint colors and codes are outlined in the following chart. The vehicle Hummer vehicles can be raised on a hoist for service access. Drive-on and swivel arm hoists are both acceptable. Hoist ca- Jacking can be performed at the front, rear, or at any one pacity and width are important. They flat bed tow equipment. This is important with full time four wheel drive vehicles. A member and secure to tow sling Figure 1-15. Flat tow- Insert 4Ó... Starting BATTERY can be performed with a portable starting unit, separate booster POSITIVE TERMINAL batteries, or the battery in another vehicle. Certain Cautions and Warnings must be observed when jump starting a vehicle. To keep track of the hours of severe operation, an optional hourmeter can be installed at your Hummer dealer. ¥ Inspect condition of control arms, springs, and shock absorb- ers. NOTE: After your vehicle has been driven for 63,000 miles 101,400 km repeat the schedule indicated in this section, starting at 3,000 miles 4,800 km. Master cylinder approximate capacity is 1. Brake system approximate capacity is 3. No other re- The oil filter is located on the driver side of the engine frigerant is recommended. Proce- dure is as follows: Replace the filter element every 6,000 mi 9,600 km , or annu- Drive vehicle until transmission ßuid is at normal operating ally, whichever occurs first Figure 1-21. IDLER ARM 4 800 km , or semiannually, whichever occurs first. If operat- FITTINGS ing conditions are severe, service at 1,000 mi. Failure to use the and adjust level as necessary. If fluid is hot, level should be be- proper fluid may affect brake performance or damage brake tween ÒHOTÓ... Description JÐ42557 Cam Socket Brakes Tool No. Description Ð Disc Brake Tool Kit 42553 Steering Tool No. Description JÐ24319-B Steering Linkage and Tie-Rod Puller JÐ25033-C Pump Pulley Installer JÐ33141 Adapter Fittings used with J-25323 JÐ25034-C... Description JÐ33142 Axle Shaft and Seal Installer JÐ21786 Pinion Rear Bearing Cup Remover JÐ21787 Pinion Front Bearing Cup Remover JÐ8611-01 Rear Pinion Bearing Race Installer JÐ29162 Rear Retaining Seal Installer JÐ8608 Rear Pinion Bearing Race Installer JÐ39524... Use the contents tables to avoid random searches for sis, turbocharger service, and diesel engine repair and overhaul. A table of contents is provided that lists the various repair Specifications for diesel engines are located at the end of this items and the section page number where repair information is section for quick reference. It is dead center on the intake and power strokes. The extra oil pres- a liquid cooled, four-stroke, 90¡... Waste gate position in Hummer vehicles, is API classification CF-4 Figure 2-3. Base stock or synthetic oils are equally acceptable. This type of solvent does not leave a residue that interferes with sealer cure or adhesion. All Hummer models are equipped with a fuel filter warning Carbon deposits can be emulsified by some spray type gasket lamp. This is because the bearing may knock at both ends of piston travel. The purpose of road testing is basically to confirm or deny the existence of an engine fault. It is a mixture prior to combustion. STUD FUSIBLE 00-S02-001 LINK Figure 2-6: Checking Current at Each Glow Plug OIL PUMP PRESSURE TEST Connect the pressure test gauge to the transmitter fitting in the valley of the block. Pressure should be a minimum of 6 psi 41 kPa at hot idle and increase to 30 psi 207 kPa at 2000 rpm. InsufÞcient cranking speed below 100 rpm 1. Check, repair cables or connections. Recharge bat- cold or 180 rpm hot. Replace batteries if shorted, sul- Caused by: phated, damaged. Wrong fuel or poor quality fuel. Drain and reÞll tank. Purge rest of fuel system and When Hot bleed injectors. Air leaks in fuel supply suction lines. Starter or solenoid problem. Check for bad or loose connections at starter and Crank - solenoid. If OK, note if starter surges when current Continued is applied. Poor Accelera- tion 2. Low grade diesel fuel. Drain tank and refuel. Sludge or wax buildup in fuel Þlter low fuel 3. Drain and reÞll tank with better quality fuel. Check and correct timing. Engine coolant entering combustion chamber 3. Prolonged high speed, high load, or overload 1. Reduce overload, or speed as needed. Incorrect oil grade used for high ambient 2. Switch to SG, SH-CD oil with SAE viscosity rat- temperature operation. Check thermostat and cap operation. Replace continued either part if inoperative. Check coolant ßow and replace pump if necessary. Lubrication is by engine oil CROSSOVER from the engine lubrication system. HOUSING Boost is monitored by the PCM and controlled by the waste- gate and electronic accelerator pedal. It signals pedal position to the PCM. At boost detent position, The wastegate valve controls boost. It is operated by the vac- the potentiometer signal causes the PCM to close the wastegate uum actuator. Do not reuse old O-ring as leakage may occur. Remove turbocharger heat shielding. Problem is in fuel delivery system. Check fuel Acceleration volume or pressure. Remove nut securing engine bracket to stud on starter motor Figure 2-12. Raise engine enough to remove insulator, or bracket Figure 2-12. The repair procedures described in this section cover engine service that can be performed in the vehicle. Loosen but do not remove crankshaft pulley bolts Figure 2-14. Remove serpentine accessory drive belt as follows: Loosen drive belt by rotating belt tensioner in counterclockwise direction Figure 2-15. Smooth surface with Þle, or 280 grit paper, if necessary. Install pulley on damper and install pulley bolts. Tighten TORSIONAL bolts until snug. DAMPER Install serpentine belt on all pulleys except belt tensioner Figure 2-16. Remove crankshaft pulley and torsional damper. Refer to Removal procedures in this section. Remove oil seal front cover with tool J 22102 or pry tool 2. Loosen and remove serpentine drive belt. Remove injection pump driven gear Figure 2-24. Remove baffle from front cover Figure 2-24. Remove nuts and washers attaching fuel injection pump to studs on front cover Figure 2-24. NOTE: There are timing marks on the front cover and injec- tion pump. Install new seal in front cover with tool J 22102. Apply sealer to front cover as follows: 1. Install new camshaft thrust plate and spacer if required. ¥ Use anerobic sealer, such as Loctite 510, on cover 2. Then install damper attaching washer and bolt. Tighten bolt to 140-160 lb-ft 190-217 Figure 2-28: Front Cover Mounting N¥m torque. Install fan pulley, fan, and fan clutch. Tighten attaching nuts to 15-20 lb-ft 20-27 N¥m. Install serpentine drive belt. Connect heater and bypass hoses at water pump and crossover. Then attach radiator upper inlet hoses to inlet tube. Remove transmission and transfer case assembly. Using small screwdriver or seal puller, remove old seal Remove flywheel. Remove front console and engine cover. Remove studs and bolts attaching rocker arm cover to cylinder head Figure 2-34. Remove air horn and inlet hose. Then remove air cleaner assembly. This product will Drain engine coolant. Clean cover mounting rails on cylinder head with brake or 8. Install fuel injector line clamps and harness and sensor contact cleaner and shop towels. This product will remove brackets on manifold studs. Tighten retaining nuts to 26 residue from surface and ensure proper adhesion of new lb-ft 35 N¥m torque. Refer to Lift and remove each rocker arm and shaft assembly procedures in this section. Do not intermix assemblies if they will be reused. Install rocker covers and intake manifold as described in Carb cleaner or a spray type gasket remover can be used to re- this section. Install heat shield and exhaust manifold on cylinder head and tighten capscrews to 25 lb-ft 34 N¥m. Remove right exhaust manifold rear heat shield screws and locknuts Figure 2-38. Remove console and engine access cover. Detach rear heat shield from transmission fill tube clamp Figure 2-39. Remove rear heat shield. Install rear heat shield. Remove intake manifold and gaskets. Note attaching stud and bolt locations for reinstallation reference. Cylinder Head Left Side 13. Disconnect driver side fuel injector lines at pump and injectors and remove lines. Cover injectors with duct tape Removal to prevent dirt entry. Install rocker arm and shaft assemblies. Be sure pushrods are properly seated in lifter and rocker arms. Do this Installation before tightening shaft retainer bolts. Install shaft retainers 1. Clean gasket surface of cylinder block with scraper if nec- and bolts. Install fuel injector lines. Tighten line fittings at pump and ¥ Glow plug relay and bracket injector to 19 lb-ft 26 N¥m torque. ¥ Engine wire harness clips and ground wires 13. Install intake manifold and gaskets. Apply sealer to rocker arm cover. Use RTV-type silicone, Installation adhesive-sealer such as Loctite 592, or Permatex High Temp, Ultra Copper, or Ultra Blue. Allow sealer to cure 1. The lifters are not repairable. A failed lifter must be replaced as an assembly. Service access to the lifters requires removal of one or both ROLLER cylinder heads. Tighten new cap nuts to 44-52 through lifter. Remove lifter from container and wipe it dry with lint 7. Replace main bearings as follows: free cloth or paper. It consists of left and right manifold BEARING JOURNAL halves and a center manifold. Remove consoles and engine cover for access to turbo- charger inlet pipes. For information regarding inlet pipes, Installation refer to Section 3. Remove bolts attaching radiator and shroud assembly to frame and brackets. Then with aid of helper , remove Anaerobic and RTV type sealers are both used during engine radiator, shroud, condenser, and oil coolers as an assembly re-assembly. Working under vehicle, loosen, disconnect, or remove 43. Attach lifting sling to engine Figure 2-59. Install battery tray and batteries. Connect positive and adapter and connect it to compressor. Install new seal washers. Install seals and cover plates on air lift brackets. Notched HOSE ADAPTER side of seals face engine. Insert spanner J—41240-1 in holes in water pump pulley Figure 2-62. Use spanner to hold water pump shaft and wrench J— 41240-5A to loosen nut securing fan clutch to water pump. If pump requires service, remove pump attaching bolts and remove pump from bracket Figure 2-67. MOUNTING BRACKET PUMP PULLEY POWER... Remove bolts and studs attaching each manifold half to cylinder head. Tap each manifold half with rawhide mallet to loosen it. GASKET Lift and remove manifold halves and gaskets Figures 2-70 GASKET and 2-71. Loosen clamps and remove fuel return hose from injection 1. Remove injection line support bracket from studs Remove fuel return hoses and clamps from injectors Figure 2-77. Remove cover attaching bolts and studs. Remove fuel injectors and gaskets Figure 2-79. Remove rocker arm cover. Remove cylinder head bolts Figure 2-81. LIFTER REMOVER J—29834 2. Remove cylinder head from block. Remove cylinder head gasket. Repeat procedure for opposite cylinder head. OIL FILL TUBE ADAPTER PLATE ADAPTER PLATE GASKET WATER PUMP Figure 2-85: Water Pump, Adapter Plate, and Gasket Disassembly WATER PUMP Fuel Injection Pump Removal Remove electrical connections, fuel inlet and return lines from pump. DRIVE GEAR DRIVE KEYS 2. Remove bolts attaching front cover to oil pan. Remove bolts attaching front cover to engine block. Loosen bracket clamp screw and rotate bracket off mounting stud. Remove shavings - chips afterward. Paint mark pistons for assembly reference. Remove flywheel attaching bolts with impact wrench and suitable size socket. Verify that the tubes are clear Figure 2-101. Check all of the block surfaces for nicks, scratches, cracks, damaged threads, or evidence of porosity at any point. Minor nicks and scratches can be smoothed with a fine tooth file or CAM BEARING AND BORE LOCATIONS... Replace any plugs that are loose or leaking. Remove and replace any pins that are Coat replacement plug threads with Permatex 2, or high temp loose. Remove the piston rings, insert the piston in the bore, and BORE GAUGE check piston-to-bore clearance with a feeler gauge. Replace the crankshaft if runout is greater than Clean the crankshaft with solvent and clear the journal oil specified. Do not attempt to straighten a cast iron crankshaft. Discard rings after removal. BOTTOM Use a ring groove tool to remove carbon and oil deposits from COMPRESSION the ring grooves. Avoid going to the largest oversize piston unless absolutely necessary. Install rings in sequence: oil ring first, bottom compression ring second, and top compression ring last. Piston Ring Installation Use ring expander tool J—42525 to install the rings. Wipe the 180 grit emery. Remove stem seal from valve and slide valve out of guide and head. OIL FILLER TUBE Remove shim. On exhaust valve, also remove nylon stem and guide seal Figure 2-134. Remove remaining valve assemblies in same manner. Inspect the faces for pitting, cracks, or burnt segments. Also inspect ACCEPTABLE the lock grooves at the stem top. Be sure the grooves are free of CRACK LENGTH cracks, worn or broken lands, or chipped spots. Scuff sand all gasket surfaces with 180 grit paper. Clean the valvetrain parts and cylinder head with solvent RETAINER and dry with compressed air. Install new freeze plugs in heads if necessary. RETAINER AND BOLT Immerse the lifters in solvent and use a pushrod to stroke the lifter plunger. The pump is serviced only as a complete as- sembly. Individual pump parts are not available. The pump shaft, pickup tube clamp and bolt, and pump mount- HUB BORE ing stud are all available as service parts Figure 2-148. Inspect the adapter fitting and bolt for damaged threads NOTE: The filter bypass and cooler bypass valves can be re- Figure 2-149. The manifolds can all be immersed in parts cleaning solvent. Small dents, not involving stretched metal, are not a cause for Carbon buildup in the exhaust manifolds can be removed with replacement. Install main bearing caps and old bolts retained from disassembly operations. Tighten the inner 12 mm bolts to 55 lb-ft 75 N. Retighten the inner 12 mm bolts to 55 lb-ft 75 N. Tighten the inner 12 mm bolts an additional 90 degrees. Clean gauging material off crankshaft journal. Lubricate rod bearing halves and crankshaft journal AND BEARING FIT with engine oil or assembly lube. Then reinstall rod cap and Verify correct piston and rod assembly. Install retainer and pump shaft in oil pump. Apply high temp bearing grease to upper end of shaft. Install sprocket drive keys in camshaft and crankshaft Figure 2-167. THRUST WASHER FLYWHEEL AND BOLT BOLTS 6 TIMING MARK INJECTION LOCATIONS PUMP DRIVE GEAR... Install new seal in front cover with installer tool J—22102. Install injection pump gasket on front cover studs. Apply Permatex 2 to both sides of gasket and install gas- 2. Mount injection pump on front cover studs Figure 2-169. Prime valve lifters in kerosene then engine oil. Then pump plunger with ADAPTER PLATE FRONT pushrod to force solution through lifter. Lubricate lifters with oil and install in cylinder block. Position guide plates on lifters. Handle the gasket with care and make sure the gasket surface is not creased or HEAD dented. Install glow plugs in each cylinder head Figure 2-178. Apply RTV-type sealer to cover sealing surfaces. Apply Permatex 2 to crossover gaskets and position gas- kets on cylinder heads Figure 2-185. Attach fuel lines to injectors and pump. Verify line routing and connection Figures 2-183 and 2-184. Install damper key in crankshaft Figure 2-186. Apply Permatex High Tack to manifold gaskets and posi- tion gaskets on cylinder heads. Lubricate crankshaft hub, damper seal contact surface, and damper hub bore with engine oil or chassis grease. The proce- dure for reprogramming TDC offset is as follows: 1. It performs five func- the powertrain control module based on inputs from the elec- tions which are: tronic accelerator pedal and various engine sensors. The The main and auxiliary fuel tanks are made of high density nozzle is threaded into the cylinder head and positioned so the polyethylene. The pump contains a fuel solenoid driver, an optical and fuel temperature sensor, a shut off solenoid, a stepper motor, and a fuel solenoid. The PCM controls operation of all of the engine and transmis- Inspect transmission linkage and wiring connections, sion outputs. Fuel contaminated, low quality, or wrong Drain off sample at fuel filter drain plug. Excessive amount of water or wax buildup in 1. Draw off sample at drain plug. Sluggish Accel- High fuel temperature. Normal condition in high ambient. Contaminated, incorrect, or low quality fuel. Air leak in fuel delivery system. Inspect injector line fittings. Bleed injectors and tion. PART OF FITTING The scan tool is connected to the vehicle electrical system J—29079-125 AND LINE ADAPTER KIT... Replace nozzle if fluid falls off tip in less than 10 seconds. Test injector chatter as follows: Close test tool shutoff valve. Connect scan tool and start engine. If the wiring tests OK, replace the solenoid. The sensor is located at the top of the injection pump ad- 3. Install the O-ring seal above the threads at the bottom of jacent to the fuel shut-off solenoid. Drain the engine coolant and remove the upper radiator NOTCH hose from the thermostat housing. Remove the left intake manifold runner to gain access to the Fuel Solenoid Driver on the left side of the injection pump. The motor is controlled by the PCM SCREWS and is actuated by input signals primarily from the coolant, air, STEPPER MOTOR and fuel temperature sensors. Four reference teeth 90° Connect voltmeter between PCM terminal BRA5 and apart, on the crankshaft timing sprocket cause the devise to ground and crank engine. For example, as throttle opening increases, sensor 1. Vacuum readings on the 2. Remove air cleaner Figure 3-23. Install dust unloader on air cleaner. Remove ring clamp, cover, and gasket from air cleaner Figure 3-25. Loosen induction hose clamps. Remove hose from air horn and air cleaner Figure 3-26. WEATHERCAP AIR HORN AIR INTAKE... Remove air cleaner assembly. Remove three screws and drainage bracket from body Figure 3-29. Drain tank with recommended equipment. Remove bolts attaching fuel filler housing to body. UPPER STRAP Remove vapor canister shield and bracket. Then disconnect tank vent lines, and hoses at branch tee in fuel filler housing. Drain tank with air powered por- seated and secured. PLATE SERVICE Secure gasket and transmitter to access plate using same Removal method as indicated for access plate above. The valve is electrically operated The valve is accessible from under the vehicle. Disconnect the by a switch in the passenger compartment. Connect sensor and fuel heater harnesses to body harness Removal connectors. Loosen the hose clamps securing the CTIS compressor if Connect drain hose to fuel filter. Remove filler tube housing bolts. Disconnect fuel pump wiring harness Figure 3-43. Disconnect filler tube vent hose. Install cap on rear injector nipple Figure 3-46. Remove return hose from injection pump and tube Install injector connecting hose. Remove fuel injector from necessary cylinder. INJECTOR PORT Using torsional damper bolt Figure 3-47 ,rotate crankshaft to bring affected piston to TDC position. Diesel Injection Line Bracket And Clamp Install bracket on valve cover studs Figure 3-51. If removing rear injector, remove console and engine cover. Remove fuel return hose and cap from injector Figure 3-52. Disconnect fuel return hoses from necessary injector Figure 3-53. Install clamps on injection lines Figure 3-54. The turbo diesel electronic injection pump is not serviceable. Only the pump solenoids, sensors, gaskets, and drive gears are 2. Connect injection lines to pump Figure 3-55. If value is not within specified or other components affecting timing are replaced. Remove nut, lockwasher, lead, and sender from engine Disconnect battery ground cable. Remove console and engine cover. Organic Contamination NOTE: The fuel quality hydrometer provides a general indica- Diesel fuel systems are susceptible to fungi and other micro-or- tion of fuel quality and should not be considered to be scientif- ganism infestation when water is present. Remove fasteners attaching muffler to tailpipe. Remove fasteners attaching muffler to frame bracket and insulator. Loosen tailpipe and transfer case exhaust pipe brackets. Remove old muffler and install new muffler and gasket. Loosen or remove necessary frame brackets and clamps that retain converter and pipe Figures 3-61 and 3-62. Remove passenger side exhaust manifold rear heat shield. Description J—26925 Mag-Tac Engine Tachometer Procure from Kent-Moore. At high temperatures, fluid viscosity decreases and NOTE : Off-road driving in extremely dusty conditions may more fluid circulates through the cooler maintaining an even result in debris entrapment between the radiator and oil cooler. Remove hood Section 10. Attach lower mount and radiator to frame bracket with 10. Connect upper and lower radiator hoses to radiator. Do not tighten Figure 4-5. Use bolts to attach power steering cooler to brackets. Remove radiator and fan shroud. Remove screws and shroud shield assembly from airlift bracket Figure 4-9. SHROUD AIRLIFT BRACKET SHIELD ASSEMBLY REAR SUPPORT BRACKET Figure 4-10: Insulator and Rear Support Bracket Location SURGE TANK REPLACEMENT Removal... Connect surge tank-to-lower radiator hose to surge tank. Connect radiator vent hose to surge tank. Connect overflow hose to surge tank. Fill and purge cooling system. VENT HOSE RADIATOR SURGE TANK BRACKET OVERFLOW... Drain cooling system as necessary. Loosen clamps and remove lower radiator hose from radiator and lower tube assembly Figure 4-16. Secure lower tube assembly to frame bracket with bolts, washers, and locknuts. Remove drain valve from lower tube assembly Figure 4-17. Loosen clamps and remove water pump inlet hose from Figure 4-19. Drain engine coolant below level of water crossover. Remove bolts attaching thermostat cover to crossover housing. Remove thermostat cover and gasket Figure 4-22. Insert square lug of half-inch drive breaker bar in belt ten- Removal sioner. Then move tensioner counterclockwise to loosen Insert spanner J—41240-1 in holes in water pump pulley belt Figure 4-32. The 4L80-E is a four-speed, auto- put shaft speed. Solenoids are used to actuate the shift valves matic transmission with fully electronic shift control. The plate contains the model, electronically controlled. Failure of the sensor constitutes wiring har- ness replacement. Solenoid A controls the 1-2 shift valve while Solenoid B controls the 2-3 shift valve. Both sole- EXHAUST noids are mounted on the valve body and operated by the PORT PCM. The torque converter clutch TCC solenoid is located on the At low throttle openings, the PCM applies a maximum of 1. The electronic accelerator pedal input signals inform the PCM of throttle position. This input affects pressure control solenoid operation and transmission line pressure. Run engine at curb idle The Hydra-matic transmission used in Hummer vehicles is ser- speed. Only external parts are serviced during the Remove dipstick and check fluid level. If engine and transmission have cooled down, drive vehi- Shift problems such as harsh, or late shifts, indicate a problem cle 10-12 miles to return to normal operating temperature. Fill the reservoir to the suggested level. Check for PCM trouble codes, both current and Go to the Diag- Go to step 3 history. Fluid capacity of the 4L80-E used in Hummer vehicles is: 2. Connect pressure test gauge to transmission. An incorrect fluid level can lead to shift problems, fluid breakdown, and accelerated wear. Check fluid level and condition during the preliminary inspec- FRONT LIFT HANDLE tion procedure. DTC P0218 is stored in PCM history. P0560 Sysem Voltage Malfunction The PCM inhibits TCC engagement. The PCM freezes shift adapts. The PCM turns off the PC Sol. The PCM illuminates the MIL. The PCM inhibits TCC engagement. The PCM inhibits fourth gear engagement. The PCM commands increased line pressure. Modulation Solenoid Circuit Electri- The PCM inhibits TCC engagement. The PCM inhibits fourth gear engagement. The PCM freezes shift adapts. DTC P1860 is stored in PCM history P1870 Transmission Component Slipping... Optical sensor 5 volt reference... The proper correction may be transmission replacement. Contact the AMG warranty department for direction in such cases. Remove valve body and repair as needed. In Neutral Forward clutch fault. Vehicle Moves Manual linkage loose, damaged, misadjusted, 1. Overdrive roller clutch failure. Valve body fault: Remove and free-up binding valves. Replace switch assembly if failed. Worn or damaged intermediate sprag clutch. Drive In Sec- No Overrun 1. Rear band or servo fault. Main or output shaft damage. Test operation of all sensors with scan tool. Replace failed sensors as needed. Clutch Apply PCM problem. It is then drawn through the filter and transmission case into the table. Scan tool TFT display should rise steadily to about 100°... Install the scan tool. Look for possible bent, backed out, deformed or damaged ter- minals. Go to Step 2 — Install the scan tool. Is the replacement complete? Look for damaged terminals, check for weak terminal tension, inspect for broken wire. The PCM turns OFF the MIL after three consecutive igni- for a change. Connect a J— 39200 DVOM on AC Voltage scale between terminals A and B at the OSS Sensor. The PCM tuns OFF the MIL after three consecutive igni- sage the wiring harness while watching the test equipment tion cycles without a failure reported. Disconnect the OSS Sensor connector from the OSS Sensor. Connect a J— 39200 DVOM covered in Electrical Section 12 on AC Voltage scale between terminals A and B at the OSS Sensor. Go to Step 13 Go to Step 14... Fourth Overrun Direct Front Interm Rear Range Gear 1-2 Sol 2-3 Sol Roller Sprag Roller Clutch Clutch Clutch Clutch Band Clutch Band Clutch Clutch Clutch — — — — —... Go to Trans- Refer to Transmission Fluid Checking Procedure. When grounded energized by the transmission 20-way connector. When grounded energized by the applied and any gear range selected, the clutch fluid PCM, the solenoid stops converter signal oil from exhausting. Turn the ignition switch to on. Look for possible bent, backed out, deformed or damaged ter- minals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Turn the ignition switch to on. Look 1-2 Shift 2-3 Shift for possible bent, backed out, deformed or damaged ter- Gear Solenoid Solenoid... Go to step 5. Disconnect the transmission 20-way connector additional DTCs will set. Go to step 14. Using multimeter measure the resistance from solenoid terminals to ground. Turn the ignition switch on. Look 1-2 Shift 2-3 Shift for possible bent, backed out, deformed or damaged ter- Gear Solenoid Solenoid... Go to step 6. Go to step 5. Disconnect transmission 20-way connector addi- tional DTCs will set. Connect 05743837 Jumper Harness to engine har- ness connector. Preform the following procedure in order to verify the —... P0223, P0225, P0226, P0227 or P0228. Go to Step 2 —... The DTC will be cleared from history when the vehicle has achieved 40 warm-up cycles without reported failure. Go to Transmis- —... The PCM turns OFF the MIL after three consecutive igni- tion cycles without a failure reported. A scan tool can clear the DTC from the PCM history. The PCM clears the DTC from the PCM history if the vehicle completes 40 warm-up cycles without a failure reported. Go to Step 17 — Disconnect the internal wiring harness at the TCC PWM Sol. Fourth Overrun Roller Direct Front Sprag Interm. Roller Rear Range Gear 1-2 Sol 2-3 Sol Clutch Clutch Clutch Clutch Clutch Band Clutch Clutch Clutch Band Ð Ð Ð Ð Ð... Go to Trans- Refer to Fluid Level and Condition. PCM and at the transmission 20-way connector. The solenoid valve energizes or de-energizes by making or breaking an electrical circuit through a combination Perform this test before a road test in order to make sure that of switches and sensors. Place the gear selector in Low D1. Go to step 10 Go to step 14 Measure the resistance from terminal N to the transmission case. Install the J 39775 jumper on the transmis- 19-24Ω 20° Go to step 3 Go to step 2 sion 20 way connector. C 68°F Using a DVOM and a J 35616 Test Adapter 24-31Ω... The discharge will foam vigorously when the solution is introduced into the water stream. Equipment Needed Flush the oil cooler and pipes with water and solution for two minutes. Remove the discharge hose, reconnect the cooler feed and 10. Insert filter pipe in case with twisting motion. Align filter return pipes to the transmission and refill the unit to the with valve body and work into place Figure 5-30. The valve limits pressure buildup in the oil cooler and Install fill tube seal in transmission. It is not nec- essary to replace all of the lines if only one section is damaged. The transmission, transfer case, front and rear hubs, and winch In cases where plastic vent line is supplied in bulk quantity, the are all connected to a common vent line system Figure 5-34. Remove converter housing upper cover from transmission Remove crossover pipe. Remove converter housing upper cover. Remove gasket from cover. Remove lower bolts and remove cover from transmission 3. Keep the valve body level and the spacer plate in position SERVICE during removal. This will avoid losing or mispositioning the The following electrical components can be replaced once the check-balls. Overtightening or ran- dom tightening will distort the valve body resulting in valve 2-3 SHIFT bind, cross leakage, and shift problems. SOLENOID B Connect wire harness to solenoids and switch. Remove transmission as described in this section. Remove bolts attaching transmission fill tube to heat shield and intake manifold Figure 5-44. Then remove fill 2. Remove transmission harness from retaining clips. Disconnect front propeller shaft and remove rear propeller CROSSMEMBER shaft. Install rear crossmember and secure transmission mount to adapter. Connect oil cooler lines to transmission and transfer case. Be sure lines are properly secured in clamps and brackets. NOTE: Wavy washers eliminate any potential transfer case shift linkage rattle Figure 5-54. If a rattle is present on a vehi- cle not equipped with a wavy washer, install one as shown. Re- SHIFT CONTROL ASSEMBLY fer to parts manual for wavy washer part number. Disconnect backup or position switch wires at body harness. Remove driver side inner kick panel. Install switch on shift control housing and secure with 2. The shifter boot cover is made of a silicone coated fiberglass, heat resistant material. This material provides the additional benefits of reduced noise and heat intrusion from under the ve- hicle into the passenger compartment. Tighten bolts to 6 lb-ft 8 1. Install two shift control housing boot protectors. Move shift lever to manual low 1 range. Disconnect transmission shift rod from arm in shift control housing. Verify that transmission shift lever Figure 5-63 is in REAR manual low 1 range. If not, disconnect lever trunnion MOUNT and adjust trunnion in, or out as needed. The front and rear output Hummer vehicles are equipped with the New Process Gear, drive sprockets are interconnected by a drive chain model 242 transfer case. If you have questions about the trans- Figure 5-66. The tag provides the model num- ber, assembly number, serial number, and low range ratio. The transfer case shift lever is adjacent to the transmission shift Usage recommendations are: lever. A straight-line shift pattern is employed Figure 5-69. The transfer case can be shifted from High H to High Lock High Lock HL HL and back, at any legal speed without putting the transmis-... Reduce speed to 15 mph if shifting from H to HL Hard to Shift and back. Stop vehicle completely if shifting into low range. Removal Shift transfer case into high lock HL position. Unfasten snaps and pull velcro strips apart to open shifter Disconnect shift rod and trunnion at control housing shift boot cover. Mark front propeller shaft and transfer case yoke for align- ment reference. Disconnect front propeller shaft at yoke. Retain U-bolts and nuts Figure 5-76. Remove yoke nut Figure 5-77. Remove drain plug and drain oil from transfer case. Rein- stall drain plug afterward. Disconnect propeller shafts from transfer case. Disconnect wiring harness connectors from vehicle speed sensors range switch, and lock switch. Remove vehicle speed sensor and both indicator switches. Remove front output shaft yoke Figure 5-82. Remove yoke nut with suitable size socket and impact wrench. Then remove seal washer and yoke. Remove speedometer tone wheel and snap rings Figure 5-88: Rear Case Removal Figure 5-87. Remove oil pump, pickup tube, hose, and screen 8. Remove rear case attaching bolts and remove rear case Figure 5-89. Remove drive sprocket snap ring Figure 5-91. Remove drive sprocket Figure 5-92. Figure 5-92: Drive Sprocket Removal 14. Remove detent plug, spring, and plunger Figure 5-95. Remove oil cooler attaching nuts and washers. Then remove cooler, support bracket and O-rings Figure 5-95. Remove mode fork sleeve from mainshaft Figure 5-98. Note position of sleeve for installation reference. Do not disassemble fork assembly. Only the fork pads are serviceable. Remove snap ring that secures intermediate clutch shaft on mainshaft Figure 5-99. Remove differential snap ring Figure 5-101. Remove differential from mainshaft Figure 5-102. Remove mainshaft needle roller bearings and spacers Figure 5-103. NEEDLE ROLLER BEARINGS BEARING SPACERS MAINSHAFT Figure 5-103: Mainshaft Bearing and Spacer Removal 26. Disassemble input gear and low range planetary as follows: Remove retaining ring that secures input gear in low range planetary Figure 5-108. Remove lock ring and front thrust washer Figure 5-109. Remove input gear and rear thrust washer from low range planetary Figure 5-109. Remove and disassemble differential as follows: Scribe or paint mark front and rear cases for assembly reference Figure 5-110. 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. Tap old bearing out rear of front case with plastic or raw hide mallet. Remove old bearing from interior of front case as shown. Remove pilot bearing from input gear with slide hammer Use tool handle J—8092 and tool J—29170 Figure 5-122. J—2619-01, and puller tool J—29369-1 Figure 5-124. Remove old seal with pry tool. SUITABLE SIZE SEAL INSTALLER 2. Drive out old bushing with tool handle J—8092 and tool J— 33839 Figure 5-126. Position new bushing on tool J—33839 and tap bushing into place until flush with bushing bore. Assemble input gear and low range planetary: INPUT GEAR Lubricate gear, planetary, and thrust washers with Dexron III. LOW RANGE PLANETARY b. Install rear thrust washer in planetary. Be sure washer tabs are aligned in planetary notches as shown Figure 5-129 NOTE: The thrust washers are the same size and are inter-... Replace wheel if teeth are chipped, cracked, or broken. Coat needle bearing surface of mainshaft with petroleum jelly. Then install first spacer, 53 needle bearings, and remaining spacer. Install rail through mode fork, range fork, CLUTCH SHAFT MAINSHAFT and into case bore and install lock pin Figure 5-153. Install detent plunger, spring, and plug. Assemble driven sprocket and front output shaft. Use new snap ring if old one is worn or distorted Figure 5-155. Install front output shaft and driven sprocket. Then install drive chain Figure 5-156. Position pump assembly in rear case. Be sure pickup screen is seated in case notch as shown Figure 5-160. SNAP RING DRIVEN SPROCKET DRIVE DRIVE SPROCKET SPROCKET SNAP RING FRONT OUTPUT SHAFT Figure 5-157: Securing Drive Sprocket to Mainshaft Figure 5-155: Front Output Shaft and Sprocket 31. Install drain plug in rear case. Apply Loctite PST to threads of indicator switches and speed sensor. Description J—35944-AMG Transmission Oil Cooler Flush Kit J—35944-500 Cooler Line Adapters J—35944-22 Oil Cooler Flushing Fluid J—8614-01 Yoke Holding Tool J—8092 Universal Driver Handle J—25025-B... Remove support and lower corner of vehicle. Use tightening sequence shown Figure 6-3. TIGHTENING SEQUENCE HOSE SHIELD GEARED HUB SPINDLE WHEEL AND TIRE ASSEMBLY... When tire is fully deflated, use a circular pattern and d. Remove O-ring from insert. Remove O-ring seal from inner rim half. Remove tire from inner rim half. WARNING: Balance weights contain lead. Wash hands RUNFLAT after handling. Inspect outside of tire for sidewall damage. Replace tire if damaged. Inspect tread for puncture damage. If damage is too extensive for patch repair, replace tire. CORE HOUSING WARNING: O-ring sealing surfaces must be kept clean VALVE and free from rust and dirt. Damaged studs can cause improper assembly apart wheel assemblies. RUNFLAT Lay tire flat on side. Runflat COMPRESSOR should position itself inside tire. GAUGE NOTE: If vehicle is equipped with central tire inflation sys- tem, position shield mounting bracket on outer rim. INSERT Place wheel in tire inflation cage. Failure to follow proper safety precautions may result in serious injury or death. Inspect inner rim for cracked, broken, rusted, pitted, bent, or loose studs, and studs with damaged, mutilated, or deformed threads. Replace defective parts Figure 6-19. Clean all wheel, runflat and tire parts using tire buffing SQUARE solution. Position wheel on tire machine with outside facing up. NOTE: The distance between the two runflat end gaps must Lubricate tire beads and mount inside tire bead on wheel. Failure to follow these instructions may result in serious injury or death. Before installing valve core, inflate tire to seat beads. Use of tire bead seater may be required. Tire wear inspection should be performed for all vibration complaints. Resolve tire Tire tread wear is a good indicator of tire balance and suspen- wear problems before continuing with diagnosis. They are easy to use and General give a dynamic two-plane balance. On-vehicle balancing is not recommended. Locate and mark wheel and tire assembly light spot on the WEIGHT CLIP WEIGHT tire Figure 6-31. CLIP-ON TYPE WHEEL AND 4. Record weight and position readings. TIRE ASSEMBLY LIGHT SPOT LIGHT SPOT WHEEL... SPINDLE Then do the following: 1. Replace ball joint if end play exceeds the limit. Check steering center link, idler arm and tie rod ends for wear or damage Figure 6-41. Refer to alignment specifications Figure 6-42. Move vehicle onto alignment rack and position front tires If alignment angles are within specified limits, move on alignment rack turntables. A positive caster an- Verify correct caster angle at both front wheels. Be sure gle is required on all Hummer vehicles. Preferred caster angle is +2. Maximum al- Leave vehicle on rack for camber and toe adjustments. Adjust camber angle by rotating the front eccentric of the Preferred camber for all Hummer vehicles is zero to +0. Be sure side-to-side variation does not exceed 0. Position both rear wheels on alignment rack turntables. Leave vehicle on rack for toe settings and steering stop 2. This procedure should be followed if align- 34°... The CTIS allows the driver to increase or de- crease tire pressure based on terrain and climate conditions. VALVE VALVE ASSEMBLY SPINDLE Electrical Troubleshooting Symptoms are listed for system malfunctions, and procedures and corrections are diagramed to assist service technicians. Check the air pressure in each tire and compare it to the information taken earlier. Note any air pressure loss and This section contains troubleshooting information for locating concentrate on that tire position. Replace the con- Use a soap and water solution or a Damage is found nector or tube. Use a soap and water solution to on the Deflate Valve check for leaks. Check for cracks, frayed wire, stripped threads, and pressure. Remove CTIS instrument cluster panel. Replace defec- tive parts. Remove lower closeout panel and swing steering column down. Install lamps in sockets and turn one quarter turn 2. Check for WARNING: CTIS components are subject to high air cracks and stripped threads. Remove lower closeout panel and swing steering column Install instrument panel. Install the fuse box access panel in the left closeout panel. Remove the interior fuse box access panel in the left close- out panel under the instrument panel. Check for de- NOTE: Prior to removal, tag all leads for installation. Repair or replace defec- Removal tive parts. WARNING: CTIS components are subject to high air Remove air pressure switch from manifold. Always relieve air pressure before loosening or removing air system components by disconnecting CAUTION: Do not allow sealant into air system. Sealant will damage CTIS components. REPLACEMENT NOTE: Apply sealant to threads prior to installation. WARNING: CTIS components are subject to high air pressure. Raise and secure hood. Raise and secure hood. Remove the left side cowell cover and the fuse box cover. Remove left cowl cover and fuse box cover. Check for cracks WARNING: CTIS components are subject to high air and stripped threads. Sealant will WARNING: CTIS components are subject to high air damage CTIS components. Always relieve air pressure before loosening or removing air system components by disconnecting NOTE: Apply sealant to threads prior to installation. The HUMMER CTIS uses rubber hoses, nylon tubing, and re- Tape ends of new hose to prevent dirt entry. Disconnect line at front hub Figure 6-69. Loosen clamp on bracket attached to lower control arm, Remove line from clamp on lower control arm and from then move air line out of bracket Figure 6-70. Check for leaks, cracks, and stripped threads. Raise and secure hood. CAUTION: Do not allow sealant into air system. The quick-disconnect valve is a one-piece component. Damage to REPLACEMENT quick-disconnect valve will result if forced apart. WARNING: CTIS components are subject to high air Remove quick-disconnect valve from spindle. Always relieve air pressure before loosening tion shields is basically the same. Remove rear tube connection shield. WARNING: The CTIS air system contains air under 2. Remove four bolts, washers, and steering arm cover from high pressure. NOTE: Ensure that any new fittings have pipe sealant pre-ap- Perform this procedure on remaining three wheels plied to threads. Description 05710216 Internal tubeless tire repair kit 05710215 External tubeless tire repair kit... The leak point could be at a brakeline, fitting, hose, or caliper. Internal leakage in the mas- 1. CAUTION: The HUMMER is equipped with DOT 3 brake fluid. Do not mix with other brake fluids. Failure to use the proper brake fluid will damage the brake system. Check brake pads for excessive wear. If fluid is contaminated, flush system with clean brake Replace brake pads as axle sets front or rear if any pad fluid. Check for correct tire pressure. The Check brake pads for binding as a result of corrosion or dirt. Excessive seal friction in booster. Flush the steering system while pumping the Brakes Apply When brake pedal. Repeat steps 3 and 4 until fluid flows clear and free of air PRESSURE TANK bubbles. MENT Inspect rotor for heat cracks, spotting, discoloration, pitting, or scoring. Resurface rotors if discolored, pitted, NOTE: The following procedure applies to the front brake or scored. Removal WARNING: Ensure brake pads are installed with lin- CAUTION: Cover or plug all open connections immediately ings facing rotor. Failure to do this will cause poor per- after disconnecting to prevent contamination formance and damage to equipment and may result in NOTE: Have drainage container ready to catch brake fluid. Depress brake pedal slowly and hold. Loosen front brake FLANGE line to purge air from the front section of the reservoir. Install gasket and hydro-boost on cowl with four washers, lockwashers, and nuts. Do not tighten nuts. CAUTION: The HUMMER is equipped with DOT 3 brake fluid. Do not mix with other brake fluids. Failure to use the 2. Remove service brake caliper. Remove pushnut and disconnect stoplight switch rod if so Remove six capscrews, lockwashers, halfshaft, and rotor equipped from brake pedal assembly. Put transmission in PARK, chock wheels, and release parking brake. Remove cotter pin, washer, and clevis pin securing BRAKE PAD parking brake cable to lever. Apply a light coat of brake compo- Removal nent lubricant on adapter slides. NOTE: Perform step 2 only if caliper guide pins were re- placed. Put transmission in PARK, chock wheels, and release NOTE: Perform step 1 if clamp bracket was removed, if not, parking brake. Remove cotter pin, washer, clevis pin, and brake clevis Rotate bracket inward on support bracket and secure with from lever. Put transmission in PARK, chock wheels, and release NOTE: Perform step 1 if clamp bracket was removed. If not, parking brake. Remove cotter pin, washer, clevis pin, and brake clevis Rotate bracket inward on support bracket and secure with from lever. Put transmission in PARK, chock wheels, and release parking brake. Remove cotter pin, washer, clevis pin, and brake clevis from lever. Discard cotter pin Figure 7-28. Put transmission in PARK, chock wheels, and release Parking brake rod is properly adjusted if lever is in contact parking brake. Install boot on body. Install upper boot on parking brake WIRING HARNESS CLAMP hand lever. Install parking brake hand lever on body and secure with two washers, bolts, washers, and locknuts. Secure parking brake hand lever on body with bolt, nut and lockwasher assembly, wiring harness clamp, and nut and lockwasher assembly. Do not mix with other brake fluids. Failure to use the proper brake fluid will damage brake system. Remove and discard actuator shaft dust seal. Remove and discard centering pin plug O-ring. Rear Caliper Disassembly Figure 7-37 15. Remove and discard centering pin O-ring. Mount caliper in vise so parking brake lever and spring are 16. Install thrust screw as follows: a. Align slot in thrust screw with centering pin. Insert thrust screw in caliper and seat it on centering pin and on ball bearings. Compress thrust screw retaining ring with fingers and install it in caliper bore below piston seal groove. These attachments eliminate tool chatter to allow for a Cleaning and Inspection better surface finish. Make sure these adaptors are clean and free of nicks. The optional swirl pattern finish will provide the NOTE: Clean all components, examine for wear or damage, best initial braking effectiveness. Parking brake should hold vehicle stationary. PARKING BRAKE LEVER CAUTION: The HUMMER is equipped with DOT 3 brake fluid. Do not mix with other brake fluids. Failure to use the PARKING BRAKE ROD proper brake fluid will damage brake system. The start phase consists of the ABS warning light flashing The first part of the code number Figure 7-46: : A pause in the following sequence Figure 7-45 : of 2. Count the flashes until the next long pause occurs. Remove the four bolts, washers and lock washers securing the modulator bracket to the air lift bracket Figure 7-54. Removal WARNING: Batteries must be disconnected when the brake hydraulic system is being serviced and bled. If the ABS motor pump runs when air is in the hydraulic sys- tem, air can get trapped behind the valves in the modu- lator causing a spongy brake pedal. Disengage the modulator alignment pin from the mounting bracket and remove the modulator from the mounting bracket. Remove the brake line adapters, noting the position for reinstallation Installation 1. Install the brake line adapters in the same position as in the original modulator. NOTE: Left side speed sensor leads route across above the Remove the ECU enclosure hold-down bracket and lift the halfshaft cv-joint. Care must be taken to ensure the lead does top half of the ECU enclosure up and out of the pocket in not come in contact with the cv-joint. Description J—42553 Disc Brake Piston Retraction Tool J—35592 ABS Pinout Box J—44237 ABS Blink Code Jumper J—44238 Master Cylinder Bleed Adapter not shown J—42883 Wheel Speed Sensor Test Cable J—29532... The gear is also supplied by Delphi Saginaw Steering Systems. A steering fluid cooler is used on all Hummer models. The ver- tical mount cooler is located at the driver side of the fan shroud. Power Steering Component Service Most of the power steering pump components are not service- able. The seals and the flow control valve, however, can be serviced. Raise and support the front of the vehicle. Install a cotter pin in each slotted nut. Before final tightening of the sleeve clamp hardware, center both tie rod end studs in their sockets Figure 8-5. Removal CAUTION: If the stud and socket are not properly aligned, a 1. Raise and support the front of the vehicle. Thread two tie rod ends into the adjusting sleeve, turning 2. Remove the cotter pins and slotted nuts from the center them the same number of revolutions that were required link end and the geared hub end of the tie rod Figure 8-6. Raise and support the front of the vehicle. Remove the cotter pin and the slotted nut securing the 1. Remove two locknuts, washers, pivot bolts, and steering column from mounting bracket. Removal Installation NOTE: Before removing steering wheel, turn steering column Hang steering column from mounting bracket with two to gain access to intermediate shaft mounting hardware. Disconnect battery ground cable. Follow steps 2, 3, 5 and 6 of Steering Column Removal Replacement. Lock and Switch Housing Assembly Assembly Disassembly Install the shaft, bearing, and retainer ring into tube and bracket assembly Figure 8-15. NOTE: The key must stay in the ignition switch at all times. Remove three screws holding front half of steering wheel hub cover to the rear half. Disconnect battery ground cable. With transmission lever in P, turn ignition key to run. HOUSING ASSEMBLY CONNECTOR 2. Activate brake switch and move transmission lever to N. Without turning ignition key off, move transmission shift lever to P. Turn steering wheel left and right several times to bleed off power steering fluid. Remove bolt on intermediate shaft yoke at steering gear Remove three nuts, six washers, and three screws from and disconnect intermediate shaft from steering gear. Secure spacer and dust boot to cowl panel with four screws, eight washers, and four locknuts. REPLACEMENT Removal CAUTION: In step 7, do not attempt to drive the pulley onto the pump shaft with a hammer. The pulley and pump ring will 1. This procedure covers the power steering pump to hydro-boost re- STEERING turn hose and the steering gear to hydro-boost pressure hose. Disconnect two hoses from cooler Figure 8-28. The gear can be adjusted, or overhauled as needed. Overhaul requires that the gear be removed from the vehicle as repair can only be per- formed on the bench. While the charts outline common faults, they may not cover all The charts list potential faults in order of probability most possible problem causes. There is some noise in all power steering systems. One of the most common is a hissing sound most evident at standstill parking. Check for kinks in hose. Remove the kinks or replace the hose. Restriction in the Hose 2. Turn steering wheel lightly against each stop and record maximum pressure. OVERHAUL If pressure at each stop is about the same as recorded Cleanliness is extremely important to a successful gear over- in step 10, and flow drops to 0. RETAINING RING PUNCH GEAR SCREWDRIVER HOUSING Figure 8-33: End Plug and Seal Removal Adjuster Plug Removal and Disassembly 1. Rotate stub shaft counterclockwise until rack piston is ARBOR TOOL J—21552 even with seal groove in open end of housing. Do not allow the rack piston to extend out of the housing. O-RING If wormshaft remained engaged in stub shaft cap, disengage and remove wormshaft at this time. Remove seal retaining ring with internal-type snap ring Discard all the old O-rings, seals, and seal rings. Do not reuse pliers. Gear Housing Hose Seat Replacement Install bearing in gear housing with handle J—8092 and The hose seats in the gear housing Figure 8-49 , can be re- installer J—6278 or J—21551 Figure 8-50. Wormshaft flange should be seated against piston as shown Figure 8-53. LOAD BEARING BALLS INTO THIS BALL GUIDE PORT INSTALLER WORMSHAFT TOOL FLANGE J—6219 RACK PISTON GEAR Figure 8-53: Rack Piston Loading Port HOUSING For Bearing Balls Figure 8-51: Pitman Shaft Seal Installation... Install new O-ring on valve spool. Install stub shaft in valve body as follows: a. Insert stub shaft into valve body. Position new stub shaft bearing on installer tool J—6221. BEARING Position bearing so ID number is toward installer tool. This will minimize any chance of damaging the bearing during installation. Be sure wormshaft thrust bearings are not RACE OUTER displaced during installation. Mount gear in vise equipped with protective vise jaws. RING GAP Position gear so adjuster plug is accessible and wormshaft is horizontal. If adjuster plug locknut is installed, loosen nut with punch ACCESS HOLE and hammer and remove it from adjuster plug. Loosen locknut on pitman shaft adjuster screw. Remove care- Figures 8-72 through 8-77 fully to avoid losing parts. Remove fitting assembly and O-ring seal. Figure 8-78 Inspect fitting for damage. NOTE: Clean all components, examine for wear or dam- Inspect housing for damage. Inspect remaining components for damage. Replace power steering pump if any component is damaged. Install O-ring seal in bottom groove of pump body 8. Install O-ring seal in center groove in pump body 17. Install O-ring seal on pump body Figure 8-82. Install housing on pump body. Install pressure plate spring in pump body. This suspension sys- tem provides for a smoother ride and allows for more positive control of the vehicle. Place prybar between lower arm at ball joint and geared 2. Install upper ball joint on geared hub with slotted nut. Using crowfoot and adapter, tighten slotted nut to 65 lb-ft 1. Install cotter pin in slotted nut. This proce- NOTE: Control arm bushings must be replaced as a set dure covers the left front lower control arm. This procedure covers the front ing removal and installation. Failure to support lower geared hub. Apply thread-locking compound to halfshaft retaining bolt and secure halfshaft to geared hub with lockwasher and 1. Remove fill plug and washer from geared hub Figure 9-18. GEARED HUB TIE ROD END FILL PLUG SLOTTED NUT GEARED HUB Figure 9-16: Tie Rod End Into Geared Hub VENT LINE Figure 9-18: Geared Hub Fill Plug 14. This procedure Remove wheel. Remove access plug and washer from geared hub Figure 9-15. DRIVER HANDLE J—8092 6. Apply thread-locking compound to halfshaft retaining bolt and secure halfshaft to geared hub with lockwasher and halfshaft retaining bolt. Remove four bolts, washers, and steering arm cover from geared hub Figure 9-25. Drive and driven gears must be re- placed as matched set Figure 9-28. Inspect splines and gear teeth on drive gear and driven gear for damage. Place the new output seal on the installer J—44906, with the seamed side of the stainless steel perimeter facing toward the geared hub and drive the seal in until the DRIVE GEAR RETAINER installer bottoms out on the geared hub surface. Apply a thin coat of grease to boss protruding side of play. Install driven gear and bearing spacer in geared hub NOTE: If an excessive amount of torque 18-26 lb-in. Clean sealing surfaces on geared hub and side cover. Apply anaerobic sealer to side cover and install on geared hub Figure 9-34. GEARED HUB GEARED HUB SIDE COVER Figure 9-34: Geared Hub Side Cover Removal NOTE: Make sure bolts and holes are free of old Loctite. Loctite from threads of old screw and apply fresh Loctite 272 to old screw threads prior to reinstallation. Apply thread-locking compound to bolt threads and install steering arm cover on geared hub with four washers and bolts. Remove fill plug and washer from geared hub Figure 9-40. Figure 9-43: Steering Arm Cover Installation NOTE: Ensure clampnut does not move while clampnut lock NOTE: Thoroughly clean old Loctite before applying fresh screw is being tightened. Severe eye injury may result if metal GEARED chips contact eyes. HALFSHAFT RETAINING Removal BOLT 1. Push boot past groove on shaft. Install the snap ring and retaining clip into grooves on 1. Position outer boot and two clamps on shaft near outer shaft Figure 9-48. Position joint inner housing over bearing assembly. NOTE: Ensure all ball bearings are in the tracks of the inner NOTE: Axle vent line replacement procedures are basically joint. NOTE: All geared hub vent line replacement procedures are NOTE: Position clamp at a 45 degree angle toward the wheel basically the same. Remove drainplug from axle assembly and drain axle Remove brake caliper and yoke from caliper adapter dis- assembly Figure 9-53. This NOTE: Removal and installation procedures are basically the procedure covers the rear axle assembly pinion seal. Failure to do this may cause AXLE ASSEMBLY personal injury or damage to equipment. Remove four bolts and washers securing axle assembly to side mounting brackets. BRACKET Loosen locknut on output shaft assembly Figure 9-60. AXLE ASSEMBLY SEAL WASHER VENT LINE LOCKNUT LOCKNUT TAPPED OUTPUT SHAFT ASSEMBLY OUTPUT HOLES FLANGE Figure 9-60: Output Shaft Assembly Removal... Remove differential assembly, two bearing cups, and COVER shims from housing Figure 9-64. Tag bearing shims and bearing cups for assembly. Remove pinion nut and pinion yoke from pinion gear. Drive pinion gear out of front pinion bearing. Remove two differential side bearings from differential assembly Figure 9-69. Remove rear pinion bearing from pinion gear Figure 9-70. Figure 9-74: Pinion Gear 23. Install two bearing caps and four bolts in housing and 13. After the zero setting is obtained, rotate the gauge shaft finger tighten bolts. Rotate housing 180 degrees. Lubricate outside diameter of PINION GEAR PINION DEPTH pinion rear bearing cup with gear oil Figure 9-90. VARIANCE NUMBER NOTE: If pinion shim is beveled, be sure beveled side faces bottom of bearing cup bore. Install differential assembly, bearing cups, and shims in 38. Rotate differential assembly and check runout. Install two bearing caps and four bolts in housing. Snug should not exceed 0. Remove four bolts, bearing caps, bearing cup, shims, and points on ring gear and must not vary more than 0. Preload differential side bearings by increasing shim 66. Using axle shaft and seal installer J—33142, install output thickness at each side of differential assembly by 0. U-JOINT SERVICE Front Shaft Removal 1. Remove U-joint clamp bolts and straps. Then disconnect shaft yoke Figure 9-104. FRONT AXLE YOKE ENGINE MOUNT... Clean part with solvent. Inspect shaft, slip yokes and U-joints for wear or damage. Refer to procedure in this section. Remove U-bolts, attaching rear shaft to rear axle yoke 10. NOTE: Before checking suspension height, check the follow- 2. Remove grease fitting from cross Figure 9-111. Remove two bearing cups from cross rear shaft only. Broken spring coil or shock absorber. Refer to the parts... Remove brushguard, if equipped. WARNING: Winch must be supported prior to per- 2. Discard cotter pin Figure 9-119. Remove hood and hinge Section 10. Remove two locknuts, washers, bolts, and washers Installation securing front suspension brace to frame extension... Tighten locknuts to 90 lb-ft 1. Remove locknut, washer, bolt, and washer securing splash shield to bracket Figure 9-125. NOTE: Note direction of bolts for installation. Remove two locknuts, washers, bolts, washers, and bracket from frame rail. Do not tighten bolts 1. Remove swing-away spare tire carrier, if equipped Sec- Figure 9-126. This procedure covers the right front spring seat. Remove rear body mount Section 10. Removal Remove two locknuts, washers, bolts, and washers 1. Tighten locknuts to 90 1. Remove right engine mount and insulator Section 2. Remove right front body mount. Remove two locknuts, washers, bolts, and washers Remove three locknuts, washers, bolts, washers, and right securing support bracket to engine mount bracket front body mount bracket from frame rail Figure 9-132. CAUTION: To prevent equipment damage during removal and Remove two locknuts and washers securing transmission installation of transmission mount crossmember, transmission crossmember support bracket to frame rail Figure 9-134. Remove right intermediate body mount Section 10. Remove left intermediate body mount Section 10. Remove three bolts, washers, and body mount bracket Remove tailpipe hanger Section 11. Installation Install tiedown bracket on frame rail with two washers, bolts, washers, and locknuts. Remove wheel Section 6. Remove brake caliper and rotor. Remove four locknuts, washers, bolts, washers, and Remove locknut, seal washer, and output flange from tiedown bracket from frame rail Figure 9-140. Remove front lower control arms. Remove lower radiator hose. Remove radiator front mounting bracket. Remove two nuts, washers, bolts, and washers securing front crossmember to support bracket Figure 9-142. Position left and right crossmember mounting brackets on crossmember Figure 9-145. Install crossmember and mounting brackets on frame rails Remove radiator Section 4. Do not Remove right front upper control arm. VENT LINE BRACKET LEFT FRAME RAIL 10. Secure steering gear to left frame rail with three washers, CROSSMEMBER lockwashers, and bolts. Install two crossmember mounting brackets on front cross- member with six washers, bolts, washers, and locknuts. Position a string across a plumb bob point on each of the Cracks frame rail strings Figure 9-155. Place a square with one leg coincident with a frame rail NOTE: All frame welding should be heli-arc type. When performing straightening repairs with the frame on Vertical bends, except at end sections, require removal of the vehicle: frame rail from vehicle. Pull winch cables through splash shield front vehicle Winch Troubleshooting Figure 9-159. Check for jammed winch cable. Remove two bolts and clamps securing winch cables to winch. WARNING: To avoid injury, wear gloves when han- 6. Remove three bolts and control box cover from winch. NOTE: It may be necessary to remove plastic coating com- Removal pound from winch in order to perform steps 7 and 8. Mark motor end drum support, gear train assembly, and Disassembly gear end drum support for assembly Figure 9-164. Remove winch and winch cable. MOTOR SHOWN WITHOUT CONTROL NOTE: Tag leads for assembly. Loosen set screw that retains brake. Remove clutch lever and O-ring seal from gear housing. Push brake through open end of drum and remove Figure 9-165. Remove two retaining rings from gear housing Figure 9-167. Replace winch if damaged. ASSEMBLY ASSEMBLY FIRST STAGE THIRD STAGE DRUM SUPPORT MOTOR END GEAR DRUM GASKET... Install intermediate gear carrier on gear housing. Position 85 to 87 steel balls in groove of intermediate ring gear and install intermediate ring gear in gear housing 10. With drum horizontal, install brake into drum. Install two nylon thrust washers on drum. Install drum assembly on gear train assembly. Rotate drum assembly as needed to engage driveshaft, brake, and output spline Figure 9-176. Remove three nuts, screws, and brush assembly from motor housing. Remove spacer, insulator, and washer from brush LEADS assembly power stud. Secure brush assembly power stud to motor housing with insulator, washer, lockwasher, and nut. Coat armature shaft with lubricant and install in brush The winch roller fairlead provides greater functional versatil- assembly. Assemblies must be used in place WARNING: To avoid personal injury or damage, sup- of individual parts. Remove four nuts, washers, bolts, and winch from front bumper Figure 9-186. WARNING: To avoid injury, wear gloves when han- dling winch cable. POSITIVE WINCH CONTROL Removal CABLE COVER Unwind winch cable. Mark motor end drum support, gear train assembly, and Disassembly gear end drum support for assembly Figure 9-190. Remove winch and winch cable. MOTOR SHOWN WITHOUT CONTROL NOTE: Tag leads for assembly. Loosen set screw that retains brake. Remove two retaining rings from gear housing Figure 9-193. Push brake through open end of drum and remove Figure 9-191. NOTE: Intermediate ring gear comes out with 85 to 87 steel 13. Replace winch if damaged. ASSEMBLY THIRD STAGE DRUM SUPPORT INPUT MOTOR END GEAR CARRIER ASSEMBLY FIRST STAGE THRUST WASHER OUTPUT... Position 85 to 87 steel balls in groove of intermediate ring Install gasket and output ring gear on gear housing. With drum horizontal, install brake into drum CLAMP Figure 9-201. Install two nylon thrust washers on drum. Install drum assembly on gear train assembly. Rotate drum assembly as needed to engage driveshaft, brake, and output spline Figure 9-202. Remove three nuts, screws, and brush assembly from motor housing. Remove spacer, insulator, and washer from brush assembly power stud. Secure brush assembly power stud to motor housing with insulator, washer, lockwasher, and nut. Coat armature shaft with lubricant and install in brush The winch roller fairlead provides greater functional versatil- assembly. Steel pull-type lockbolt fasteners of 0. Patches can often be applied over damaged body panels, provided the damaged area is first trimmed to remove General Information sharp edges or notches which could cause the start of new Damaged areas should be thoroughly cleaned and inspected to cracks. Lockbolts are used to withstand tension loads and high-shear Center punch the flat surface. Support the back side of the loads. These fasteners are installed in their holes with an inter- rivet, if possible. The grip NOTE: Some rivet installations in the body require the rivet to length of each rivet is marked on top of its head to provide be flush with the rivet material surface. Rivets can tolerate only 0. OF RIVET PREFERABLY ABOUT Material 3X THICKNESS OF THICKER SHEET Aluminum material used for repairs should be of the same al- loy and temper as the original if possible. Paint repair parts or patches with epoxy primer before Cracks installation. Apply sealing compound to mating surfaces to prevent SHEET THICKNESS MINIMUM STOP corrosion. Crack, splits, or holes may be repaired with a glass reinforced plastic laminate repair kit. Inspection NOTE: Hood surface has a thin layer of gel coat that may ap- pear cracked in a spider web-like pattern due to hood flexing. Repairing cracks or splits. If water has leaked into the vehicle, inspect for leakage points. Remove right side crashpad. Remove bolts securing front console to body brackets and 2. Slide center console back toward rear seating area far screws from top of console Figure 10-13. Replacement Removal NOTE: Tag all leads prior to removal for installation. Tug gently on crashpad toward steering wheel to free 2. Disconnect air hose from vent duct. NOTE: All instrument panel indicator lamps are replaced basi- cally the same. Remove screws and pull gauge panel away from instru- ment panel Figure 10-17. This proce- dure covers the main light switch. CAUTION: Some connectors can be installed incorrectly and CONNECTOR cause damage to the electrical system. Tachometer mounting Pull front console away from dashpad enough to gain clamp must be installed in factory position to have proper access to wiring harness connector. Pull front console away from dashpad to gain access to ashtray frame tabs. Pull ashtray receptacle out of frame Figure 10-25. Straighten frame tabs and remove frame. Remove rivets, retainers, and insulation from engine RETAINING RING STUD access cover Figure 10-28. RINGS ENGINE ACCESS COVER 2. Remove seal from access cover. Remove retaining rings, washers, and ring studs from access cover Figure 10-29. This proce- COVER dure covers the left front seat belt on four-door hard top vehi- cles. Secure bracket to B-pillar and body with washers and bolts Secure riser to slide set with bolts, lockwashers, and nuts Figure 10-31. Remove drive screws and carpet assembly from front and vehicles except open top models and 2-door models without an back of removable load barrier Figure 10-35. Secure trim mounting brackets to B-bar with four washers from roof. Remove screws, washers, and lower B-pillar trim from B- 2. TRIM REAR COMPARTMENT Secure upper C-pillar trim to roof with nine screw and ROOF WALL washer assemblies. Secure C-pillar center trim to roof with eight screw and washer assemblies. COMPARTMENT WALL ROOF HEADLINER LOWER REAR COMPARTMENT WALL Figure 10-43: Rear Compartment Wall Location Figure 10-44: Headliner Positioning 13. Replacement Removal PANEL FASTENERS 1.
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