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I love my auto hubs. Service them once a year and shift in and out on the fly. 156k on a 90 and as long as there is no vacuum leak they have never gave me a problem. I know this don't help but your problem in the beginning may have been to heavy of grease and or a vacuum leak. I use white lithium for hub lube. Hope ya get it together. Good luck. I will never use manual locking hubs unless so equipped as on my FJ40 and Rusty.
I love my auto hubs. Service them once a year and shift in and out on the fly. 156k on a 90 and as long as there is no vacuum leak they have never gave me a problem. I know this don't help but your problem in the beginning may have been to heavy of grease and or a vacuum leak. I use white lithium for hub lube. Hope ya get it together. Good luck. I will never use manual locking hubs unless so equipped as on my FJ40 and Rusty.
I usually thread 2 of the 6(?) of the outer cap screws in the assembly to make it a little easier to manage, and You may have to jiggle and play with that a little to get it to slide in all the way. I can't see how debris could cause this as this would have screwed with you when you "set", tightened up the bolt, for the wheel bearings.This thread is getting too long.......Did you replace the rear seal? (Possibly not getting it completely flush somewhere behind the bearings?) I apologize for what may appear to be stupid questions, but I don't know the level of your mechanical ability, and if this is your first set of hubs, they can be a bit intimidating. Personally, I wouldn't have auto locking hubs. I know when I feel that click with the manuals, they are locked. Too many times hubs don't get serviced like they should, and bitter cold doesn't really help them either, so if I physically lock them in-I know they're in. Keep the updates a'comin!!
another thing that helps some times is to spin the wheel over a few times to get things set properly. Also make sure that you have not packed too much grease in there, I did that the first time and the grease was holding the parts out too far to get the outer lock ring in. I have also tapped on the main gear set with a wooden block to get it to go that last little bit