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I. Remove Existing Hubs
Before installing Warn hubs, remove existing hubs and retain components as noted:
Click on the following images to see enlarged illustration:
Some factory hubs are installed with locking cones, whichcan be difficult to remove. Two methods to dislodge the locking cones are:
1) Place a socket slightly larger than the cone againstthe hub flange and rap sharply with a hammer.
2) Place a brass punch on the end of the stud and rap sharplywith a hammer.
II. Prepare Wheel End
Toyota conversion from automatic to manual hubs requiresWarn conversion kit P/N 29918. Verify that wheel bearing adjustment is correct andthat the lock nut is tightened to the vehicle manufacture's specification.
Note: Warn Hubs are assembled at the factory with the properamount of grease.
1. Separate cap assembly from body assembly.
2. Install O-ring and body assembly on wheel end.
3. Install washers and boltsper charts below
Install flat washers, split washers & bolts/studs
Nissan Torque to 18-25 ft. lbs,
Ford, Dodge, GM torque to 27-31 ft. lbs.
Install Flat/split washers & original nuts/bolts removedearlier
Toyota/Suzuki/GEO Torque to 18-25 ft. lb.
Jeep, IH Torque to 27 - 31 ft. lb.
4. If axle shaft extends beyond the inner drive gear, installretaining ring onto the axle shaft. Toyota Only (1976-1985): if axle shaft does notextend beyond the inner drive gear, install stop plug and hex bolt (provided) inaxle shaft and torque to 10-12 ft. lb.
5. Toyota (86-Present)/GEO/Suzuki: If cap screw and spacer were previously removed, reinstall them to the axle shaft and torque to 10-12ft. lb.
6. Properly align cap gasket on cap assembly View 1. Placecap assembly on body assembly. Align guide pin in cap to relief in body (View 2).Install and tighten the socket head cap screws to 45-50 in. lb.
7. To check for proper engagement, dial both hubs to LOCKand raise the front let corner of the vehicle off the ground. Spin the lifted tire.The drive line will turn if the hub is engaging properly.
8. To check for proper disengagement, dial the lifted wheelhub into FREE and spin the lifted wheel. If the drive line does not turn and no ratchetingsound is heard, the hub is disengaging properly. Repeat step 7-7 with the right wheel& hub.
Service Kits are available. Hubs should be serviced at thesame interval as the wheel bearings. Remove in reverse order of Installation procedure(III). Then clean and lightly grease internal working surfaces. Do Not Pack theHubs with Grease, the Hubs will NOT Function Properly.
When new: Warn Hubs are assembled at the factorywith the proper amount of grease so an additional amount is not required. When servicing:A "light coat" of molylube #1 will suffice. (Note) Hubs should be servicedat the same manufacturers suggested intervals as the wheel bearings.
Set both hub control dials to "Free" andthe transfer case selector to "2WD" for free wheeling tow wheel drive.Use the "Free" position for all driving that does not require four wheeltraction. To engage four wheel drive, set both hubs control dials to "Lock"and move the transfer case selector to 4WD. Do not drive on hard surface roads inthis mode, it can result in severe torque wind-up in the gear train.
Do not move the vehicle if the control dials areanywhere between "Free" and "Lock". To do so may cause hub damage.Driving with only one hub engaged can cause damage to the front differential. Donot attempt to drive the vehicle with the hubs in the "Free" position andthe transfer case in the low range mode. This can place excessive torque on the reardrive train. To insure lubrication of the front axle, engage the hubs for a minimumof one mile monthly.
Warn Hubs are warranted directly to the first purchaseof the locking hub set; that they will be free from defects in material and workmanshipunder normal use and service for as long as said purchaser owns the locking hubs.