Bob_98SR5

Warn Manual Hub Conversion - 2nd gen 4Runner
By Richeyma

Matt Richey shows you how he changed out his factory ADD hubs and switched over to Warn's manual hubs here. The info here should also be able to be used if you use the Toyota Aisin manual hubs too.

Replacing Toyota ADD Hubs with Warn Manual Locking Hubs:

Tools Required:
- Jack
- Hammer
- Flathead Screw Driver
- 12mm wrench/socket
- Torque wrench with 12mm socket
- 4mm allen wrench

I. REMOVE WHEEL

If you need directions for this, you probably should take your vehicle to a service shop and have them replace the hubs!

II. REMOVE CENTER CAP

Place a flathead screwdriver being the center cap and tap gently with a hammer. The cap will loosen up. Use the screw driver to pry the cap all the way off.

III. REMOVE NUTS AND LOCK WASHERS


Using a 12mm wrench or socket wrench, remove the nuts and lock washers holding the ADD hub in place. If the nuts are rusted on, use Liquid Wrench or a similar product to loosen the rust.

IV. REMOVE CONE WASHERS




When the cone washers are in place, they look like regular lock washers; however, they are conical in shape (hence the term "cone washer") and are about an inch deep. You cannot pull the hub off unless each washer is removed. With a hammer, tap the outer rim of the ADD hub above each cone washer. You may need to rap the hub fairly hard a few times to get the cone washers loose. Eventually, at least one washer will pop out as illustrated in the above right picture. Note the cone washer half way off the bolt towards the top of the hub in the picture above on the right. The first one is usually the hardest one to get out, so the others should come out fairly easily. Keep hammering at the hub until all six cone washers have popped out.

V. REMOVE ADD HUB

Depending on your truck, you will either have a C-clip or a 12mm bolt on the end of the axle. Remove the C-clip or bolt. Slide the ADD hub off.

VI. WARN HUB


The Warn hub comes with very few parts as shown in the picture. There's the hub body assembly, the cap assembly, gasket, six flat washers, six lock washers, and six cap screws.

VII. INSTALL WARN HUB





The hub slides on in the same manner that the ADD hub came off. Place a flat washer and lock washer over each bolt and use the nuts removed in step III. Torque nuts to 18-25 ft. lb. Replace the C-clip or bolt on the axle. Place the gasket in the cap assembly making sure to line up the pin relief in the gasket with the pin on the cap assembly. Place the cap assembly on the hub body assembly. Again, line up the pin relief on the hub body with the pin on the cap. Use the six cap screws to secure the cap on the body.

VIII. INSTALL WHEEL AND TEST


Install wheel and tighten lug nuts. To check for proper engagement, dial both hubs to LOCK and raise the front left corner of the vehicle off the ground. Spin the lifted tire. The drive line will turn if the hub is engaged properly. To check for proper disengagement, dial the lifted wheel to FREE and spin the lifted wheel. If the drive line does not turn and no ratcheting sound is heard, the hub is disengaging properly. Repeat these steps for the right wheel and hub.