So I completed the tear down, cleaning and re-greasing of my aisin manual hubs and then proceeded to put them back together. The first one took me a bit to get used to but finally got it done and the test for engage/diengage went great. The second hub is where the problem started. I put everything back together technically perfect but when I went to test, the inner hub would not spin freely in the free position. So I tore it back down and rebuilt it. Same thing. So now I think that the tension spring that holds the pawl to the clutch was misaligned, but it wasn't. Everything was set up right, but still can't get it to spin free. Could the large spring that gets compressed between the cover and the clutch be bad? I do not see any reason for this thing not to work. Just a light coat of grease, no rust, just a big problem wrapped in an enigma shrouded in a puzzle.

 

Did you also have the clutch in the FREE position? When I first put mine together I didn't do that and the hub wouldn't spin.

Read this. It worked great for me.

Good Luck

 

both the dial and the clutch were in the free position. After tinkering around for a bit, I noticed that when I put it all together, it won't spin, but when I pull the cover out about 1/8", it will spin freely. So, can the large spring be bad, if it is not pulling the clutch all the way close to the dial?

 

If you don't figure this out by the end of the day, I'll look at my hubs and think about it. They're disassembled right now at home.

 

I appreciate all yer help...I anna say that the problem either has to be the large spring or the small tension spring that holds the pawl to the clutch. At least i know the problem is in the cover/dial/clutch assembly, because I took the cover off my working hub and put it on the non-working hub and together they worked fine.

 

Are you sure that you installed the big spring correctly? The ends of it are different.

 

Yes...the more open end of the spring goes toward the cover and the smaller end on the clutch. I even switched that around, just for laughs, and still nothing.

 

Did both of them work before you took them apart?

All I can say is completely disassemble them and carefully reassemble them using that pdf that I posted. If it still doesn't work, then I would disassemble both hubs and compare the parts from the two and see if something is defective.

Good Luck

 

Did you ever get it to work?

 

Finally got it to work. Actually went out to chehalis to a pick-a-part to get a spare hub...turns out that some guy ordered a set a week ago, so when i went in and said 'hub', the guy plopped two down in front of me. $20 bux each he says. So I snatched those up. They also got a new 1990 runner in on the lot (engine fire) so the body was in great conditiuon. Picked up a bunch of extra parts and spares, dome light, rear cargo cubby doors, mud flaps, a couple extra assist handles (O ˟˟˟˟˟ Handles), A/C clutch fan, air flow meter (slightly toasty but functional) and hub covers. I actually wasn't supposed to take all that because they had not inventoried anything yet, but before the guy noticed...I had already paid another guy and was long gone. but they did have lots of other pickups and runners out there.

Long story short, the smaller tension spring that holds the pawl to the clutch was not doing its job properly, so I switched it out with the good one from the other hub and BAM, instant working hub. Slapped those suckers on this last weekend and went out for a test wheel out in Olympia. Worked great. Noticed slight improvement in handling and acceleration, but thats about it. I like the feel of it now. Thanks for all the help..

Now its on to rotors and replacing the AC fan. Yay.