Misc Warn manual hubs disengaging

[Dirt ball]

Hey all, my 77 CJ5 . Manual Locking hubs 6 bolt, Warn M195A - I have used 4wd and manual hubs many times before, but new to the CJ. was out on Silver Lake Sand Dunes for a few days, on my last day I peaked one of the bigger dunes and just coming back up a smaller hill. My RF hub disengaged. would not reengage. noisy in 4wd with hub in locked position, but not with the hub unlocked. sounds like splines not seated. back home, I expected to find the internals of the hub to be in pieces. Nope. took every thing apart, cleaned and inspected, No debris, no issues found. reassembled the hub, still will not engage. the dial still spins easy as it should. took it back apart, reassembled it in the engaged position and tried it again. now was staying locked. I figured I would just leave that hub in the locked position at all times. did some more wheeling and it disengaged again. front hub bearings adjusted properly, no cracks, chips, damage of any sort found to the splines or locking mechanism. everything slides easy with no issues working all of the splines individually. What am I missing?

 

[CJ]

Hey all, my 77 CJ5. Manual Locking hubs 6 bolt, Warn M195A - I have used 4wd and manual hubs many times before, but new to the CJ. was out on Silver Lake Sand Dunes for a few days, on my last day I peaked one of the bigger dunes and just coming back up a smaller hill. My RF hub disengaged. would not reengage. noisy in 4wd with hub in locked position, but not with the hub unlocked. sounds like splines not seated. back home, I expected to find the internals of the hub to be in pieces. Nope. took every thing apart, cleaned and inspected, No debris, no issues found. reassembled the hub, still will not engage. the dial still spins easy as it should. took it back apart, reassembled it in the engaged position and tried it again. now was staying locked. I figured I would just leave that hub in the locked position at all times. did some more wheeling and it disengaged again. front hub bearings adjusted properly, no cracks, chips, damage of any sort found to the splines or locking mechanism. everything slides easy with no issues working all of the splines individually. What am I missing?

This is weird. I have never seen heard of this. This is considered a failsafe hub.
Are you ok with taking the outside spring loaded engage mechanism and moving the entire assembly from right to left? It's only a few allen cap screws but will quickly eliminate what component is the problem.
One thing I'm not clear on, on the initial disengagement does the hub still show engaged?
I have seen a hub with worn master splines that due to the slop and the angle of wear it overrode the spring pressure and pushed the locking mechanism up, disengage but then automatically reengaged. It made the wheel grab and clunked.
One more question, do have any traction control on the front? Locker? Limited slip?

Keep us updated.

 

[Turbogus]

Back in the '70's when I first got my '77 CJ5 I mentioned to my automotive mentor that it came equipped with Warn hubs. He said "You'd better replace 'em then" it wasn't 'till years later it dawned on me the intended pun.

 

[Dirt ball]

This is weird. I have never seen heard of this. This is considered a failsafe hub.
Are you ok with taking the outside spring loaded engage mechanism and moving the entire assembly from right to left? It's only a few allen cap screws but will quickly eliminate what component is the problem.
One thing I'm not clear on, on the initial disengagement does the hub still show engaged?
I have seen a hub with worn master splines that due to the slop and the angle of wear it overrode the spring pressure and pushed the locking mechanism up, disengage but then automatically reengaged. It made the wheel grab and clunked.
One more question, do have any traction control on the front? Locker? Limited slip?

Keep us updated.

This is weird. I have never seen heard of this. This is considered a failsafe hub.
Are you ok with taking the outside spring loaded engage mechanism and moving the entire assembly from right to left? It's only a few allen cap screws but will quickly eliminate what component is the problem.
One thing I'm not clear on, on the initial disengagement does the hub still show engaged?
I have seen a hub with worn master splines that due to the slop and the angle of wear it overrode the spring pressure and pushed the locking mechanism up, disengage but then automatically reengaged. It made the wheel grab and clunked.
One more question, do have any traction control on the front? Locker? Limited slip?

Keep us updated.

Cj is basically stock 77 drivetrain. When the disengagement occurs, the hub stays in the 4x4 position. The situation you described pushing the locking mechanism up sounds like what may be happening with mine. But instead of re-engaging it rides and makes noise. Like the splines aren't lined up. Will try swapping side to side and see if issue follows.

 

[Dirt ball]

Back in the '70's when I first got my '77 CJ 5 I mentioned to my automotive mentor that it came equipped with Warn hubs. He said "You'd better replace 'em then" it wasn't 'till years later it dawned on me the intended pun.

They just warn out

 

[Dirt ball]

 

[CJ]

Cj is basically stock 77 drivetrain. When the disengagement occurs, the hub stays in the 4x4 position. The situation you described pushing the locking mechanism up sounds like what may be happening with mine. But instead of re-engaging it rides and makes noise. Like the splines aren't lined up. Will try swapping side to side and see if issue follows.

Please keep us updated when you swap R - L. I really want to know what is the problem.