4WD Automatic Locking Hubs
- Shift transfer case lever to 2H position, and move vehicle back and forth several feet. Raise and support vehicle. Remove front wheels. Remove caliper and wire aside. Remove clutch housing assembly through-bolts from cap.NOTE: Note position and alignment of drive clutch components for reassembly reference. Ensure drive clutch assemblies are marked with "L" (left) or "R" (right).
- Remove clutch housing assembly. Separate components (if necessary). Remove snap ring, shim(s), drive clutch assembly, inner cam and lock washer. See Fig 1 . Using Hub Nut Wrench (J-36827), tighten adjusting nut to 22 ft. lbs. (30 N.m) while turning rotor to seat bearings. Loosen adjusting nut until finger tight. Ensure rotor has no free play.
- Attach spring scale to wheel stud. Tighten adjusting nut (while pulling on scale) until scale indicates preload of no more than 5.51 lbs. (2.5 kg) for NEW bearings. For used bearings, maximum preload is 3.97 lbs. (1.8 kg).
- Install lock washer over adjusting nut, with larger diameter of tapered bore facing outward. Ensure clutch housing through bolt holes align. If holes do not align, reverse lock washer plate. If holes still do not align, turn adjusting nut inward just enough to obtain alignment.
- Clean hub flange, threaded holes, lock washer surface and axle shaft splines. Ensure transfer case lever is in 2H position. Install inner cam by aligning keyway of inner cam with groove in knuckle. Inner cam gear must face outward. Tap inner cam lightly with plastic hammer to ensure contact with lock washer.
- Lower vehicle so front axle is at normal horizontal position. Hold CV joint part of axle shaft and push it outward as much as possible. Perform STEP 1. See Fig 2 . Hold inner cam with other hand to prevent moving it.
- Using Automatic Locking Hub Gauge (J-36836) and feeler gauge, select proper shim(s). Install gauge onto axle shaft until it comes in contact with lock washer plate. Perform STEP 2. See Fig 2 . Measure clearance "T" between gauge and axle shaft snap ring groove with feeler gauge.
- If clearance "T" is larger than snap ring groove, select proper shim(s) to obtain a clearance of .004" (.10 mm). Perform STEP 3. See Fig 2 . Remove gauge and leave inner cam in position. Apply multipurpose grease to axle shaft splines, drive clutch outer groove, driven clutch inner circumference and inner cam face.
- Align cut part of drive clutch with concave part of inner cam as viewed from spring side. Engage drive clutch assembly cam teeth to inner cam by turning axle shaft.
- Measure dimension L(1) between retainer surface and clutch surface to ensure proper installation. See Fig 3 . Record dimension. Install selected shims. Install Snap Ring Installer (J-36835-2) to axle. Install snap ring to installer.
- Use Driver (J-36835-1) to push snap ring into place. Pull out on axle shaft and push driver inward to install snap ring. Remove installer and driver. Ensure snap ring is secured. Measure dimension L(2). See Fig 3 . If difference between dimensions L(1) and L(2) is more than .028" (.71 mm), shim thickness is correct. Install Loctite (515) to housing flange surface. Install housing.