Hey everyone,

I am having a problem installing new manual hubs on my 94 Bronco. The factory hubs are manual so no issue there.

I did my homework first, searched this site and read a hundred threads about this. The only thing that could be a problem was that dreaded outter lock ring. So I got my tools out today and went to work.

The lock ring was an adventure but when I finally got it I realized it was not so bad. Pulled the old hub out no problem - now I'm feeling good. Got the new hub, lined it up and pushed it in. Just one minor thing it would NOT go on all the way - I'm about 1/8" to 1/4" shy of getting the snap ring on. Now I'm am not feeling so good.

I removed it, twisted it to the right unitl I felt it line up and pushed it on again - same thing. I did this several times. It will not go on far enough to get the snap ring on. I double checked the part # Warn, the old and new hubs are the same height, the new ones just will not go on far enough. I looked for some sort of alignment mark but didn't see any. I cleaned out the inside of the unit on the truck. I think I am at a loss - not sure how to proceed.

I put the old hub back on, called it a day and grabbed a cold one.

Any advice or suggestions would be greatly appreciated.

Thanks,
Mark

 

Try pulling the axle outwards. It gets pushed into the diff while the hubs are going on. You can reach around and push outwards on the u-joint.

 

Thanks mprice! I read about this when I was doing my homework. I didn't see any movement but I might have missed it. The old hub went back on no problem. I will give it a try this morning.

I also read not to use any grease, if anything use a little graphite or WD40 to help slip it on. I mention this because the new hub is a very tight fit. It's time to get to work.

I am determined to get this done today.

Mark

 

A light film of grease wouldn't hurt anything if that helps get it back together. IMHO, that would be better than graphite or WD40.

 

Thanks again! Started first thing this morning, got the old hub out no problem - put the new one in, pushed the axle out - it did move a little - it helped but I am still shy by 1/8". I measured the inner splined ring on the hubs, the old one is 1 3/16", the new one is 1 1/4". There is a threaded sleave over the axle for the lock nut - I think this is where it is stopping.



I am not sure if the washer behind the lock nut is installed correctly and I don't see how that would allow that sleave to move farther back. So, I went out to get prices on a torque wrench and spanner - $50 or more. Either I buy or rent the tools and hope that washer is the problem or just give up and take it to a shop.

Thank you for your help!
Mark

 

That threaded sleeve is called the spindle. If that's truly your problem then you have the wrong hubs. The axle itself has quite a bit of inboard/outboard movement. It seems likely to me that you aren't getting the axle out far enough. Stick a big screwdriver in the axle u-joint and make sure you push it ALL the way out. You won't break anything.

Don't use WD40. It's a jack of all trades but master of none. It's not a very good lubricant.

 

Thanks andym! I double checked the part # the first day. Warn #9790 all web sites and parts stores list the same one. They look identical to the factory hubs, same height, design, ETC. The only difference is the inner splined clutch ring on the Warn is a 1/16" longer.

I pushed the axle outward yesterday morning maybe I didn't push hard enough. I can get the hub in far enough to get the outter lock ring on but I checked for movement and it is tight - will not move at all. I'm just a little shy of getting the inner snap ring on. If I can get it with a little more muscle will it be OK? I have read there should be a little play in the hub and like I said it is tight.

Thanks again for your help.

Mark

 

Here is an idea for you: since all the pieces are the same, except the "inner splined clutch ring", why don't you use the old ring with the new Warn gear?.

 

Encho - thanks for the idea. It is described in the instructions as the splined clutch ring - the inner part of the hub assembly that is splined for the axle shaft. It's confusing - sounded like I was talking about the snap ring. Warn told me there has to be a washer and an inner clip on the axle and to remove those. I swear they are not in there.

I didn't have time to work on it yesterday or today so I am going to give it another shot tomorrow.

Thanks,

Mark