Warn's Fusible Hublocks.
Remove the six Allen bolts...
Remove the six Allen bolts that retain the dials of the locking hubs to the hub bodies. Pull the dial covers.
Pop out the snap rings with...
Pop out the snap rings with snap-ring pliers.
Pry out the ring clips that...
Pry out the ring clips that hold the hub bodies inside the wheel hubs. Two small screwdrivers work best.
You may have to wiggle the...
You may have to wiggle the assemblies a little to get them to slide out. Pull the hub bodies out by threading in a couple of the Allen bolts to use as handles.
The Fusible Hublock is on...
The Fusible Hublock is on the left. Notice that the inner teeth are longer and therefore stronger on the standard hublock (right).
Remove the ring clips on the...
Remove the ring clips on the locking hubs so the standard hublocks can be replaced.
Lightly grease the new hublocks...
Lightly grease the new hublocks and install them in the hub bodies using the supplied ring clips. Reinstall the locking hubs on the Jeep, and youre done.
Snapping axles, stripping the teeth off of ring-and-pinions, and pulverizing steering U-joints is expensive. Its hard to determine what will let loose first when youre throttling up some rock thats itching to eat steel. Wouldnt it be great if you could break the same inexpensive part every time, kind of like a fuse in an electrical system? Warn recently introduced its Fusible Hublocks that can do just that for your driveline.
The Spicer 297 steering U-joint has become a fairly common breaking point for abusive drivers. Its much stronger than the 260s found on earlier Dana 30s (pre-95), but its weakness often pushes some people to run Dana 60 front axles. The 297 U-joint will fail at approximately 55,000 in-lb with the wheels pointed straight ahead. Its important to remember that the amount of force a U-joint can handle decreases as the steering angle increases. The Fusible Hublocks are designed to strip out at about 46,000 in-lb. In a straight-shot throttle attack the hublock will fail first. If the wheels are turned the U-joint will fail before the hublocks.
The Fusible Hublocks can be retrofitted into Warn locking hubs if you have the current 3-inch internal-mount models. The Fusible Hublocks are not recommended in axles with Detroit Lockers. The teeth on the locker could be damaged when the hublock fails. Installation of the fuses is simple; heres the how-to.