Warn Manual Locking Hubs
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Tuned
Joined: Sep 2015
Posts: 393
Likes: 60
From: Vermont
Warn Manual Locking Hubs
I have the heavy-duty version on my '97, if they are in the "lock" position, will they not disassemble off of the axle? I ask because I began to disassemble but the inner splined part of the hub body stays on the axle shaft (yes I removed the circlip on the end of the axle). I realized then that I needed brake pads, so I put it all back together until Friday. All of the YouTube videos show the unit sliding in/off in one piece. When I try to slide it off, it's a mechanical "thunking" sound as it slides about 1/8" then stops. Any hints? I saw nothing about the position of the lock in any literature.
Lead Driver
Joined: Mar 2006
Posts: 5,111
Likes: 1,549
From: western SD
There should be a spring clip circling the wheel hub on the inside. Remove the 6 screws that hold the outer locking hub on, remove the c clip from axle shaft, (some dana 60s do not have this), remove the spring clip from the inner wheel hub, and the assembly should slide out. I usually screw on of the outer hub screws in to use to pull the assembly out.
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Tuned
Joined: Sep 2015
Posts: 393
Likes: 60
From: Vermont
Is the "spring clip" for retention or just the spring that provides tension/compression? There was one (spring) behind the cover cap and one behind the outer body that I could slide off when removing the one Philips retaining screw. I believe I did what you said and the interior section, the piece that slips over the axle itself remains. There is a thick 1/4" thick brass spacer ring with 6 notches in it like you'd use a special socket to remove it, but it just spins deep back in there. That, and another piece behind it, sit in front of the 2-1/2" spindle nut.
So you are saying also that having it in it's "locked" position should have no effect on its removal?
So you are saying also that having it in it's "locked" position should have no effect on its removal?
Lead Driver
Joined: Mar 2006
Posts: 5,111
Likes: 1,549
From: western SD
The spring clip is a flat, spiral spring that keeps the inner part of the locking hub in place. It makes no difference if the hub is in the lock or free position when removing, as when the 6 screws are removed, and the outer part of the locking hub is removed,. it allows the hub to unlock. The early model hubs has a wire looking spring clip, with the later ones had the flat spiral clip. Sometimes that clip is a beach to get started to remove.
https://www.ebay.com/itm/27316802321...AZ0FFAJoIViYIe
The spring clip I'm talking about is in the bottom right in the pic in the link. If you are talking about the phillips head screw in the inner part of the hub, you don't have to remove that to get the inner part out of the wheel hub. That screw just keeps the inner assembly together. When removed it should look like the one in the link.
https://www.ebay.com/itm/27316802321...AZ0FFAJoIViYIe
The spring clip I'm talking about is in the bottom right in the pic in the link. If you are talking about the phillips head screw in the inner part of the hub, you don't have to remove that to get the inner part out of the wheel hub. That screw just keeps the inner assembly together. When removed it should look like the one in the link.
Thread Starter
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Tuned
Joined: Sep 2015
Posts: 393
Likes: 60
From: Vermont
Thanks man, yeah perfectly clear I just had forgotten about that flat spring. I'll try again and see what I see. Odd part is that when I did the ball joints on the other side, I don't remember having any issues with it other than removing that first flat sprint as you stated, and finding the 2-1/2" axle nut socket. I love wrenching but these stupid little issues really give me pause. On the up side, it's going to be 54* in Vermont on Friday which will make it a bit easier.
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Tuned
Joined: Sep 2015
Posts: 393
Likes: 60
From: Vermont
So what the problem ended up being was that the snap ring on the backside of the main body that holds the unit together had fallen off and tweaked in such a way that it was holding the inner gear set on the spindle. After some pulling with a couple of large picks, it came free.
BAck on all 4 now, thanks for the insights.
BAck on all 4 now, thanks for the insights.
8th Gear
Joined: May 2025
Posts: 8
Likes: 2
Snap Ring?
Hello defdes. I am having the same exact issue you were describing here...where was the snap Ring located?
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Tuned
Joined: Sep 2015
Posts: 393
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From: Vermont
Oh man. It’s been such a long time I was hoping that reading all of that would jog my memory, but it didn’t. Can you find an exploded view of the hubs? You might have to pull off the other side to compare or look for a disassembly video on YouTube. It sounds to me like I removed the coil spring and reaction either side of the guts to trap the other snap ring.
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8th Gear
Joined: May 2025
Posts: 8
Likes: 2
Inner Hub 2
It's the smaller gear and bronze ring that slide right on the axle. The whole thing slides about an eighth of an inch and then I can feel it catching something. Was the snap ring lodged behind that bronze ring in the back? I was thinking of using a gear puller on it if it is just the snap ring jammed in there.
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Tuned
Joined: Sep 2015
Posts: 393
Likes: 60
From: Vermont
Those snap rings are pretty sturdy spring steel, I think they might win that fight. Since I noted that used 2 picks, I would get a good light sources and feel around along either side of the guts to dislodge it.
8th Gear
Joined: May 2025
Posts: 8
Likes: 2
Yeah I got that one out and the whole outer part of the hub locker. It's the inner section that is stuck on the axle. I got the one out on the other side no problem but this one is catching. I will try to fish some pics back there later today and see if I can feel what is catching.
8th Gear
Joined: May 2025
Posts: 8
Likes: 2
Solution
Wound up getting it off. Here are some pictures of what my brother and I believe it was. Wound up just prying the hub off the axle from the backside. Once it was off we could see what the issue probably was. We believe that tiny snap ring on the back of the bronze ring was seated in such a way that it got caught up it that groove on the axle for the other snap ring. The snap ring that holds the thrust washers in place got destroyed in the process, so if you wind up doing that you will need a new snap ring. I am just writing all this in case someone else runs into the issue down the line. Thanks for the help everyone!
