Manual hubs will NOT unlock

[rockgrabber]

I have a newly acquires 1985 Bronco with manual front hubs. I replaced the spindle bearing on the passenger side shortly after I bought the Bronco. When it came time to reinstall the hub, I took the driver side off and copied what I saw. Skip ahead 2 weeks (this past Sunday) and had the Bronco on a lift and noticed that when I turned the front wheels (either side) with the hub in free position, the axle moved with it.  In the locked or free position, the axle remains locked and turns with the wheel. I removed the hub cover, spring w/ plastic piece, the ****** and the inner gear, items 1-10 in the diagram.....the wheel still remained locked, axle moved with the wheel. My hub has a spring that goes behind number 10, but it is not shown in this diagram.  I would appreciate any help you can give me. 

 

[miesk5]

yo rock,

Operational Test; "...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 engaging properly. TO CHECK FOR PROPER DISENGAGEMENT, dial the lifted wheel hub into FREE and spin the lifted wheel. If the drive line does not turn AND you hear NO ratcheting sounds, the hub is disengaging properly. Repeat step 5- 6 with the right wheel & hub. NOTE: The hubs are not required to seat against the wheel housing when installed, they may move in and out quite easily. This “float” is normal and will not affect performance..."
Source: by Warn®

http://warn.iwebcat.com/imgVD/WAR/61420C0-pn20990.pdf

Also, for posterity;

"...Manual Hub OPERATING INSTRUCTIONS: ONLY use fingers to turn dials. DO NOT USE PLIERS. Set the hublock dials to “FREE” and transfer case to 2-high for all driving that does not require four wheel drive. To engage four wheel drive set the hublock dials to “LOCK” and set the transfer case to 4-high or 4-low. Return the transfer case to 2-high before disengaging hublocks. Do not drive on hard surface roads in 4-wheel rive because it can cause drive train damage. Do not move the vehicle if the hubs are anywhere between “FREE” and “LOCK” or it will damage the hublocks. Driving with only one hublock engaged can cause drive train damage. Driving with the hublocks in ”FREE’’ and transfer case in 4-low can cause drive train damage. To ensure lubrication of the front axle, engage hublocks for a minimum of one mile monthly..."
Source: by Warn®

"...The t-case disconnects the front driveshaft from the transmission, and the hubs disconnect the axleshafts from the wheels. The driveshaft is ALWAYS connected to the diff & axleshafts. Depending on how tight your diff is, both axleshafts MAY turn when you turn the d'shaft while BOTH hubs are unlocked, but at least one of them has to no matter what. If the d-shaft won't turn with both front wheels off the ground (or the hub locks removed), then the t-case is still in 4. If either axleshaft won't turn with its hub UNlocked AND the t-case in 2 or N, then that hub is stuck locked. I suspect you'll find some carmelized grease, and some surface rust on the lock rings, and probably a spring or 2 heavily rusted, to the point that they're ruined. But that's just a guess. Take both hub locks OUT of the hubs, and then roll the truck a little. You don't need to remove the tires, or even jack the front end up since the locks don't bear ANY weight. If the d'shaft still turns, the problem is in your t-case....."
Source: by Steve

 

[rockgrabber]

Steve nailed it, the transfer case is stuck in 4wd....no amount of shifting, going forward or reverse would stop the front d'shaft from turning. I believe the hubs are stuck as well.....with both front wheels off the ground, the front axle shafts turn with wheel no matter if in lock or free position.

I figure I have three choices:

• sell or scrap it as is.
• decide to trailer it and only use it off road, in which case need to buy a car trailer, a daily driver and borrow Dad's Suburban when I want to play.
• fix it myself or find a good mechanic

Of course this weekend was to be my first ever off road experience. Was supposed to meet Carolina Bronco Club in URE. Wonder how my wife's KIA would fare on the easy trails.......

 

[rockgrabber]

Hold the phones.....tried a theory, spun back tires in 2wd, spun all four in 4wd high....the transfer case is fine!!!!! The hubs are another matter....