angrybob

The PO installed Warn hubs and I am converting back to Aisin manual hubs now. Th Warn's function fine but the mounting bolts loosen over time and for me that's NFG. The install seems like it should be very straight forward, yet the clutch seems to not be fully disengaging. It makes a ratcheting noise when I spin the wheel (with the other side on the ground in 'Lock').

I have printed out the Warn installation instructions found here (a pdf download not a web page) and there does not seem to be any additional parts added or removed for its install. I also have the FSM and have viewed the rebuild thread from space-junk here and scuba here.

I have taken apart the hubs I bought and checked everything out. All is there, including the little spring and ball-bearing. I've cleaned & regreased everything with a light coat and based on the above info, I am pretty sure the hub is reassembled correctly. Installed on the truck, the action is smooth.

The Warn instructions state "Lock both hubs and lift one wheel off the ground. If it spins, its engaging properly" & "Set the lifted wheel to "Free", if it does not spin and does not make a ratcheting noise its disengaging properly". Both sides make a ratcheting noise (and I can see the CV tick back and forth with each ratcheting noise) when the lifted wheel is in the "Free" position and the wheel on the ground is locked. I have an ARB front locker and don't know if that would change things.

I know there is interference between the teeth of the clutch and on the hub because I spun the wheel with only two finger tight bolts holding the cover on, spun the wheel, back the threads out a turn, pulled the hub back that amount and the ratcheting noise went away.

Number of splines is correct
I have the OE axle bolt and 'spacer' that fastens the hub body to the axle shaft
I used only a light coating of grease
Flat side of the large spring is against the pawl

Questions:
Are there different manual hubs for different years of IFS: 86-95?Wabfab site suggests no
What would cause the hub not to disengage all the way?
What am I missing?

Any help would be appreciated.

wyoming9

iTrader: (1)

Would you want to sell or trade your Warn Hubs??:jessica::jessica:

I Have far better luck with the Warn Hubs. I have 3 new sets to install when it gets colder.

I guess one has problems with the nuts coming loose if you wheel the truck hard with lots of hard impacts..

Maybe you put to much grease on the parts and the surface tension is holding them from releasing. It does not take much.

nothingbetter

lock washers and loctite sounds a lot easier...

waskillywabbit

iTrader: (-1)

Forget the WARN stuff in your post it's confusing what you're talking about.

What's the issue with the Aisins?

86-95 min truck pickup Toyota Aisins all the same

:wabbit2:

angrybob

I read that on Friday and wiped off all the grease last night and applied just a thin coat. Still same problem.

Problem is that when I spin the wheel or drive the truck with the hub in the "FREE" position, there is a clicking/ratcheting noise on both sides. It engages the 4WD perfectly.

I fastened the cover on using only two of the six 10mm bolts hand tight. Still makes the noise. When I back both cover bolts out 1 turn and pull the cover away from the hub that same amount, the noise is gone and the teeth are fully disengaged.

I know there is interference btwn the teeth on the ID of the hub clutch and the OD of the teeth attached to the axle shaft. Those two sets of teeth are not completely disengaging from one another are making the ratcheting noise.

Difficult to explain. I'll post something on youtube tomorrow morning.

angrybob

Been there. Done that. Torqued to 23 ft-lb and blue loctite. Wheeling 3 times since then and they all had torque to tighten values around 8 ft-lbs this morning. It took a full 1/3 turn to get each back to 23 ft-lbs.

Admittedly, I have not tried new lock washers.

Might be my next step if I can't get this sorted.

wyoming9

iTrader: (1)

I wonder if you put on two gaskets if that would move things enough for it to work like it should.

For whats it is worth I always use new hardware with my hubs if I have them off to do the bearings .:jessica:

waskillywabbit

iTrader: (-1)

I understand. Where did you get these Aisins?
Sounds like they've been bastardized perhaps or the clutch mechanism is put together wrong.

http://www.se4rj.com/forum/showthread.php?t=293

3rd post.

:wabbit2:

angrybob

Thank you very much. This makes the most sense for my problem:



With the SFA one on the left, it would make sense that I have the taller SFA clutch.

Amazing - I bought these from a long time member here as 'just rebuilt'...with a broken pawl, squared off o-rings, damn near frozen dials, old grease, and now *possibly* the wrong clutch.

Sweet.

My clutch thickness is 14mm. Any chance you could confirm the two different thicknesses next time you're at the shop?

Anyone currently have their hub apart? Knowing what type you have and its thickness measurement will ID what I have.

Again...thanks.

waskillywabbit

iTrader: (-1)

They are the same measurements except height.

Most folks have no clue on Aisin hubs I've learned and with most being 20+ years old who knows who has screwed them up.

:wabbit2:

angrybob

Will do and much appreciated.

The benefit to all of this is that I now know (by force) and understand how the hubs work, come apart, and go together.

Heh - height is probably a better word than thickness...

wyoming9

iTrader: (1)

It seems like the IFS Hub outer gear measures about .470" which is 12mm The SFA ones go about 14mm

angrybob

Thank you very much!

It seems as if I have the wrong outer hub gear / clutch. Totally sucks, but mystery solved.

Thanks wabbit for the lead to this problem and wyoming9 for the measurement.

waskillywabbit

iTrader: (-1)

I've seen it just a few times. Mostly just on one hub in a pair.

First noticed it in a pair I received to refurbish and when I finished they claimed I messed them up. Now I take pics of every pair I get in to refurbish before and after and measure parts.

Glad we fixed it.

:wabbit2:

wyoming9

iTrader: (1)

Is that the only real difference between the two styles??

Can you just swap the outer part and be good to go.

Or are the inner parts also different ??

angrybob

http://www.se4rj.com/forum/showthread.php?t=293

Its all explained there. Some parts are and some parts are not interchangeable. I learned a lot this week