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Warn warning?


Denisefwd93

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1994
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4.0
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stock, may get leveling springs in front "somday"
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94 Dana 35, older warn locking hubs, I was a happy camper driving to get ice cream cone about 3 miles then all of a sudden: Snap! Clunk, Buzzzz. Same sound the automatic Hubs used to make on my other truck wtf?

Could it be the axle bearing?

Too dark and cold outside right now.
Is this an omen? I have new manual hubs on the truck I'm going to sell!

switch them over?
 


bobbywalter

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sawzall?
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My credo
it is easier to fix and understand than "her"
likely a bearing and hopefully the lockout survives.
 

Denisefwd93

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Location
South East PA
Vehicle Year
1994
Make / Model
Ford
Engine Type
4.0 V6
Engine Size
4.0
Transmission
Manual
2WD / 4WD
4WD
Total Lift
stock, may get leveling springs in front "somday"
Tire Size
235
My neighbor came over we did it in the dark (with a light of course) it's the left side (driver)
Axle turns ok, not really noisy, the hub has a split in a plastic ring with little fingers that goes around a bearing, lots of grease no pieces of metal.
We put the wheel on without the locking hub, it spins well, smooth not too loose, no growl or rumble.
The locking hub definitely made a buzzing noise in reverse and click rolling forward when unlocked.

Not even planning on working on the 4WD until fall maybe even winter so don't really need locking hubs at this time.
 

Denisefwd93

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Location
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1994
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Ford
Engine Type
4.0 V6
Engine Size
4.0
Transmission
Manual
2WD / 4WD
4WD
Total Lift
stock, may get leveling springs in front "somday"
Tire Size
235
I really thought it was the clutch it was so loud, I don't know, I justget a little paranoid with all this stuff it's kind of overwhelming I'm retired I shouldn't be going through this but my situation doesn't allow me the money to do anything else with,

The new pre bled clutch Hydraulics are very tight right up to the top no play whatsoever the clutch disengages and engages like it should we did not change the clutch because we're planning on an engine swap in the winter.
 
Last edited:

bobbywalter

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Location
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FORD mostly
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BIGGER
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Automatic
2WD / 4WD
4WD
Total Lift
sawzall?
Tire Size
33-44
My credo
it is easier to fix and understand than "her"
Was it engaged?

When you turn the front driveshaft do the axles rotate freely?
 

Denisefwd93

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Location
South East PA
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1994
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Ford
Engine Type
4.0 V6
Engine Size
4.0
Transmission
Manual
2WD / 4WD
4WD
Total Lift
stock, may get leveling springs in front "somday"
Tire Size
235
Oh yes checked very easy to turn, that over 2 weeks ago, and the hubs only need to fee wheel

I'm hoping it's just the excessive grease inside the Hub I'm really hoping, but my luck is not that good lol
 
Last edited:

bobbywalter

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Location
woodhaven mi
Vehicle Year
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Make / Model
FORD mostly
Engine Type
V8
Engine Size
BIGGER
Transmission
Automatic
2WD / 4WD
4WD
Total Lift
sawzall?
Tire Size
33-44
My credo
it is easier to fix and understand than "her"
Ball joints are tight and arms brakets and bushings good?


Dont know how warns self engage and pop.



Odd issue. Spooky
 

Denisefwd93

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1994
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Ford
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4.0
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Manual
2WD / 4WD
4WD
Total Lift
stock, may get leveling springs in front "somday"
Tire Size
235
Ball joints are tight and arms brakets and bushings good?


Dont know how warns self engage and pop.



Odd issue. Spooky
I don't think it's self engaged it may have been engaged I don't actually know, the hubs been on and off so many times the past week it may have been engaged. anyhow tomorrow is another day taking a break
 
Last edited:

Denisefwd93

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1994
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Ford
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4.0 V6
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4.0
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2WD / 4WD
4WD
Total Lift
stock, may get leveling springs in front "somday"
Tire Size
235
Think I'll just leave that hub off until I get new hubs or parts.

Until I sell my other truck, this 94 beast isn't my daily driver. and I only drive it to check it out things that are fixed, then it goes back in the yard.
 

Denisefwd93

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Location
South East PA
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1994
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Ford
Engine Type
4.0 V6
Engine Size
4.0
Transmission
Manual
2WD / 4WD
4WD
Total Lift
stock, may get leveling springs in front "somday"
Tire Size
235
Well looks like this trucks going to become my daily driver next week I may be selling the 93 long bed!!

Apparently parts are not sold for the Ranger warn premium locking hubs!
So I'm at a loss until I can afford to get new hub/s!
 

bobbywalter

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Reaction score
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Points
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Location
woodhaven mi
Vehicle Year
1988
Make / Model
FORD mostly
Engine Type
V8
Engine Size
BIGGER
Transmission
Automatic
2WD / 4WD
4WD
Total Lift
sawzall?
Tire Size
33-44
My credo
it is easier to fix and understand than "her"
dont leave the lockout off if your driving it....if you have to, use heavy plastic bag or whatever to seal it and make sure your studs have enough thread and the wheel dont bind on the caliper. you may need a spacer.


you can buy the warn lockouts. not cheap.
 

Denisefwd93

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Location
South East PA
Vehicle Year
1994
Make / Model
Ford
Engine Type
4.0 V6
Engine Size
4.0
Transmission
Manual
2WD / 4WD
4WD
Total Lift
stock, may get leveling springs in front "somday"
Tire Size
235
dont leave the lockout off if your driving it....if you have to, use heavy plastic bag or whatever to seal it and make sure your studs have enough thread and the wheel dont bind on the caliper. you may need a spacer.


you can buy the warn lockouts. not cheap.
Yep I bought a set for my other truck they ain't cheap then I'm finding out there's no parts available so I'm not happy about that even though the ones I have on this truck are quite old

3 hours looking and working at this thing, seems like the spring doesn't hold the gears separate and when it's put it back together right way, (near as we can tell) the gears actually mesh with each other regardless of the knob setting.

But after 3 hours we still can't figure out why/how it happened!
 

Denisefwd93

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Reaction score
74
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Location
South East PA
Vehicle Year
1994
Make / Model
Ford
Engine Type
4.0 V6
Engine Size
4.0
Transmission
Manual
2WD / 4WD
4WD
Total Lift
stock, may get leveling springs in front "somday"
Tire Size
235
Update, ( kinda sorta)
Reassemble Johnny 5!!
The plastic bearing "cage" it snaps around the bearing but behind the bearing snap ring that is towards the rotor. This is a sealed bearing that is turning whenever the wheels are in unlocked/ freewheel mode.

When the knob is turned to locked mode, the outer spline gear fits inside the hub housing but slide towards the rotor and over the spline!

We still don't know what made it partially locked, chattering, clicking and buzzing while it was on the wheel my only guess would be that it was partially locked and the grease kept the splines partially engaged,
It's absolutely is not necessary to have any grease in there! If there is any at all it should be around the bearing itself which is basically a sealed bearing, near impossible to go bad.

No disassemble Johnny 5!!
I probably should take pictures but it's all back together and I'm not in the mood to take it apart again!
 
Last edited:

87xjmike

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My warns do the same thing. They cick at me and i can hear it nust going straight at lower speeds. Maybe ill take all the grease out. Still work great but damn they're.

Sent from my LG-H700 using Tapatalk
 

Denisefwd93

Well-Known Member
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Messages
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Reaction score
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Location
South East PA
Vehicle Year
1994
Make / Model
Ford
Engine Type
4.0 V6
Engine Size
4.0
Transmission
Manual
2WD / 4WD
4WD
Total Lift
stock, may get leveling springs in front "somday"
Tire Size
235
I often solve engineering problems while trying to sleep at night!

it seems to me, the grease can get behind the outer spline gear which has notches in it that slide in the corresponding notches in the housing, because the grease goes down the center where the knob has little ramps that push the outer Gear in they would actually push the grease under the outside of that spline gear creating a hydraulic Dam.
 

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