Warn Locking Hubs Acting Weird...

[bigposer]

Second post. Again, Limited mechanical know how, but I'm learning , so please excuse if my terminology is off.

My left WARN Locking Hub seems to automatically move from the "free" position toward the "locked" position after I drive it in 2WD for more than 10 miles.

I figured it out when there was a rattling/grinding sound I could hear when going over 15 mph. It never fully moves into "locked" position, but consistently migrates away from "free" position, even if I click it into "free".

Any thoughts as to why this might be happening?

 

[Torxhead]

I have have them not fully lock after doing a disassembly for a seal replacement. Then I have to readjust the locking mechanism. There is a "Star" adjuster in there with a wave like spring. It is not a complicated unit and parts can be purchased separatly for them, or at least they used to be. I haven't searched, but there must be some maintaince info out there on the web with pictures. Another thought might be a loose u-joint or wheel bearing.

 

[bigposer]

I have have them not fully lock after doing a disassembly for a seal replacement.

How difficult was disassembly?

 

[Torxhead]

I have very little info on the disassembly of the hublock, maybe there is something online:
http://c452191.r91.cf2.rackcdn.com/images/bcsq/image/61420c0-pn11967.pdf
I found this, but have never used it.
I just removed the cap assembly, turned it into the lock position, and notice the stop block that prevents the "Star" from rotating. By pushing the "Star" fingers up and over the stop block, I was able to adjust it. I have the internal locking hubs btw. If yours appears damaged, hublock or drive flange, you might be better off replacing it.

 

[mtnwhlr]

Sounds like it's time to buy some new hubs. If it were me. Sounds like they are shot.