H2 160K Overhaul
 

Long story short our 03 H2 lately started to show sings of fatigue, finally last weekend following a friend in blue down GS Parkway at unsafe speeds to say the least we melted the selector fork in the TC. 4 locked is not fun on the black top. Since there is nothing nearly as original looking on the market as an Hummer SUV time to give some love after our H2 has given so much to us.

I did this to many times with my LR not to believe it's not going to snowball on us.

Short list:

-Transfer case rebuild
-Drive shafts rebuild
-Front diff re-seal
-CV joints
-Tie rod ends
-Driver front drive hub
-Repack rear wheel bearings
-Transmission chip
-Conserve under carriage
-Ignition coils
-Injectors
-HVAC control head
-Trace horn problem
-Assortment of upholstery problems
-Update the stereo


The truck is up and dis-assembly has begun and it's a mess under there!!!













Dealer quote "anything between 2.5k and 6k" can you say Ballpark figure LOL!!!









:D

Re: H2 160K Overhaul
 

Looks like you got a good bit of work to be doing. And why would you drive on dry pavement in 4hi lock???

I have done it in emergency situations like once i broke a 1/2 shaft and did not have a spare. I had to drive it home for 55 miles.

Re: H2 160K Overhaul
 

TC locked it's self, no selector fork, can't unlock.


Little progress today, TC out and drive shafts.


That's where those vibes where from, balance weights missing.






Water contamination.







Wasn't supposed to unbolt the adapter :mad:




:popcorn:

Re: H2 160K Overhaul
 

I assume your doing all this work yourself ?

Re: H2 160K Overhaul
 

Did my hubcap oil pan give me away?:shhh: Lol, yes it's happening in my garage.

Re: H2 160K Overhaul
 

More progress today...



Man this bolts are on there!


Driver side needed some persuasion to come off.




Both sides are gone. Any one need a trail spare?


Got to keep things labeled.

Re: H2 160K Overhaul
 

Kudos to you. I wish I had the know how to do that kind of work myself. I'm sure you'll save a ton of money, but you'll endure the frustration.

Re: H2 160K Overhaul
 

Anybody can do it Haynes RM got step by step. And so far I used like only three different sockets. This one haven't been that bad so far, actually nothing compering to my other one.



Oooooooooo that's right I'm the enemy! LOL!!:D

Re: H2 160K Overhaul
 

Come to think about it, why all the bolts so far on this truck are metric? Feels like I'm working on my Rover.

Re: H2 160K Overhaul
 

Diff is out



Cross member rusted to ****!






Got to research upgrading to a Elocker.

Re: H2 160K Overhaul
 

What is that?

Re: H2 160K Overhaul
 

it looks like.....

you will need a bigger socket!

not sure if it is metric tho..

Re: H2 160K Overhaul
 

I'd say this thread automatically qualifies jarek m far beyond the misnomer, "Hummer Novice."

Re: H2 160K Overhaul
 

Thanks VegasGuy.:beerchug:

Re: H2 160K Overhaul
 

Just made this a family activity. Putting wife to work.

Re: H2 160K Overhaul
 

Parts washer was the best money I ever spend.



Little sand blasting and ready for paint


That cleaned up nicely.

Re: H2 160K Overhaul
 

I'm at 123K and just replaced original air bags on the rear suspension. Water pump is just starting to weep a little bit. I need to start putting together a to-do list.

Re: H2 160K Overhaul
 

Cracking the T Case.



:eek:

Re: H2 160K Overhaul
 

Our rear air was a $1K three visits at the dealer NIGHTMARE!!!!! But I'm glad we kept it.

Re: H2 160K Overhaul
 

:eek:


now, im no professional mechanic, but i think the spring thingy was the cause of your problems... everything else looks good!

Re: H2 160K Overhaul
 

this is some impressive DIY work. i wish i had the balls to do this. i would say knowledge too, but i think you would throw the hanes book at me like what was posted earlier.....

im just scared with all the little parts, because i normally end up with "Spare parts" after i work on things that arent suppose to have spare parts..

Re: H2 160K Overhaul
 

I thought that the fork was supposed to melt before the race comes apart?:notallthere:

Re: H2 160K Overhaul
 

Holly s**t me to, I thought it was only me.LOL!

Re: H2 160K Overhaul
 

All washed, need parts and ready for reassembly.

Re: H2 160K Overhaul
 

Farther down the rabbit hole.



More moisture.


WTF is that?




That diff is massive almost twice as big as a Rover diff!


This bushing is ok?

Re: H2 160K Overhaul
 

:fdance: :fdance: :fdance: :giggling: :giggling: :giggling: Lucky Dog you ;)

Re: H2 160K Overhaul
 

I still got to take more stuff apart, but today I made a step forward

-Trace horn problem. DONE!


Tracing the problem up the wire harness.






I changed this piece before.



Spindle.




I changed it for a new one, just forget to take ALL of the old one out!



Rust everywhere. WTF.

Re: H2 160K Overhaul
 

Diff ready to go back in.:excited:

Re: H2 160K Overhaul
 

Front diff got installed today. Piece of advice to any one doing this, power wash the undercarriage before reassembly!!!
Holly crap how can a truck be so rusted with that amount of grease underneath it.





Well deserved!

Re: H2 160K Overhaul
 

A great job!!Keep those pictures coming!!:perfect10s:

Re: H2 160K Overhaul
 

Putting that front diff back in single handedly is a real chore! lol. I had to do it by myself on my back in my driveway when I put my locker in.

Re: H2 160K Overhaul
 

:iagree:

Re: H2 160K Overhaul
 

Got the TC parts this week, thanks to Brodie at http://www.ridgedemon.com/ :beerchug:
My chain looks same as new one, no more play or wear then the old one. But I'll still change it, we all know it would break the second I would put it back together otherwise.


My new (to me) mirror got here this week to.
This one besides the obvious damage, the fold motor is bad.






All done can't test it, the battery is dead





Tomorrow is the big day slapping the TC back together! I sure could use a manual for it :winkie:, anyone...anyone...

Re: H2 160K Overhaul
 

$1.5k in parts this week, it all had to go in today.

Don't even ask me why...










Ooo, you want your car back then I suggest you get to work!


Everything that comes of got to get paint.



Tomorrow TC goes back in and Drive shafts.

Re: H2 160K Overhaul
 

Re: H2 160K Overhaul
 

Very nice. I have already decided that when my Hummer is old and tired it is going to be rebuilt/restored and kept going. Why spend the money on a new rig, when nothing else will compare. Spend it on the one that's paid for and make it the way you want it.

Re: H2 160K Overhaul
 

After working on it, I must say that this truck looks like it was build as a 3500 truck. If it wasn't for the plastic interior it's pretty solid truck.

Re: H2 160K Overhaul
 

TC is in !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!:beerchug:





It wasn't that bad

Re: H2 160K Overhaul
 

Got the drive shafts.









Trying to repaint the trim.

Re: H2 160K Overhaul
 

Unfortunately the A/C does not work it also doesn't want to switch between outside and inside air, the controller goes a little crazy when I select that. Don't the unit got to be programed by the dealer? I think I read that somewhere.