Warn(er) Auto Locking Hubs
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Description
The Automatic Locking Hub, shown in Fig. 6, engages or disengages to lock the front axle shaft to the hub of the front wheel. Engagement occurs whenever the vehicle is operated in 4WD. Disengagement occurs whenever 2WD has been selected and the vehicle is moving rearward. Disengagement will not occur when the vehicle is moved rearward if 4WD is selected and the hub has already been engaged.
Before disassembling a unit for a complaint of abnormal noise, note the following:
1.To obtain all-wheel drive, the transfer case lever must be placed in 4L or 4H, at which time the hub locks will automatically engage.
2.To unlock the hubs, shift the transfer case lever to 2H, then slowly reverse the vehicle direction approximately 10 feet.
3.An incomplete shift from 2WD to 4WD, or disengagement of only one hub lock may cause an abnormal sound from the front axle. Shift to 4WD to stop the noise, then unlock the hubs as previously stated.
Removal
1.Remove 5 screws retaining the cover to outer clutch housing.
2.Remove cover, seal, seal bridge and bearing components.
3.Compress the wire retaining ring and remove the remaining components from the hub.
Disassembly
1.Remove snap ring from groove in hub sleeve, then turn clutch gear until it falls into engagement with the outer clutch housing. Lift and tilt the drag sleeve to unlock the tangs of the brake band from window of inner cage, then remove the drag sleeve and brake assembly. The brake band must never be removed from the drag sleeve. The spring tension of the brake band can be changed if the coils are overexpanded and could affect hub operation.
2.Remove snap ring from groove in outer clutch housing, then pry plastic outer cage free from inner cage while inner cage is being removed.
3.Pry plastic outer cage tabs free from groove in outer clutch housing, then remove outer cage.
4.Remove clutch sleeve and attached components from outer clutch housing.
5.Compress return spring and hold the spring with clamps, then position the assembly in a vise so that the vise holds both ends of the clutch sleeve. Remove retaining spring.
6.Remove clamps holding the return spring, then slowly open the vise to permit the release of the return spring in a safe manner. Remove retainer seat, spring and spring support washers from the hub sleeve.
7.Remove C-ring from clutch sleeve. It is necessary to position sleeve assembly so that the C-ring ends are aligned with legs of cam follower, allowing removal between the legs.
8.Remove conical spring from between cam follower and clutch gear, then separate cam follower from clutch gear. Do not pry the legs of the cam follower apart.
Assembly & Installation
1.Install tangs of cam follower over flats of clutch gear, then compress conical spring and position with large diameter located against clutch gear.
2.Position clutch gear assembly over splines of hub sleeve. The teeth of the cam follower should be located at the end of the hub sleeve with no splines, and the clutch gear and spring should slide freely over splines of hub sleeve.
3.Install C-ring into groove of hub sleeve, then install a spring retainer over each end of return spring.
4.Position one end of return spring with retainer against shoulder of clutch gear, then place support washer on end of the return spring. Compress return spring and install retainer ring into groove of hub sleeve.
5.Place assembled components into outer housing. The cam follower should be positioned with legs facing outward.
6.Install 3 of the cover screws into 3 holes of the outer clutch housing. These screws will support the component to permit the clutch hub to drop down so that the tangs of the brake band can be assembled.
7.Carefully install the plastic outer cage into outer clutch housing with ramps facing toward cam follower. The small external tabs of the plastic cage should be located in wide groove of outer clutch housing.
8.Install steel inner cage into the outer cage, aligning tab of outer cage with window of the inner cage, then install retaining ring into groove of outer clutch housing above outer cage.
9.The brake band and drag are serviced as a complete assembly. Install one of the 2 tangs of the brake band on each side of the lug of the outer cage, located in the window of the steel inner cage. It will be necessary to tilt these parts to engage the tangs in this position as the drag sleeve is positioned against the face of the cam follower.
10.Remove the 3 screws and rest the end of the hub sleeve on a suitable support, then install washer and snap ring above drag sleeve. The following steps may be completed as the hub is installed into vehicle.
11.Install wire retaining ring into groove of end of clutch housing without spline. The tangs of retainer ring should point away from splined end of clutch housing.
12.Hold the tangs together and install the 2 bent down tabs of seal bridge over tangs. The seal bridge holds the wire retainer ring in a clamped position in groove of outer clutch housing. Install O-ring into groove of outer clutch housing and over the seal bridge.
13.Lubricate and install the bearing over the inner race. The steel ball bearing should be visible when the bearing is properly installed.
14.Install bearing retainer clip into hole in outer race, then install bearing and retainer assembly in end of hub sleeve. Install seal ring over outer clutch housing.
15.Install bearing race spring into bore of cover, then install cover and spring assembly. Align holes in cover to holes in outer clutch housing and install 5 screws.
16.Install O-ring over seal bridge to prevent it from dislodging during handling prior to the hub bearing being installed into the vehicle.
17.The hub and attached parts should turn freely after installation. The 5 cover screws must be loosened to install the hub into the vehicle. After installation, torque the cover screws to 40---50 inch lbs.
