SAX-WH 86-95 Suzuki Samurai (Sidekick, X90, …blog.lowrangeoffroad.com/wp-content/uploads/instructions/...CAUTION: Safety glasses should be worn at all times when working with vehicles

CAUTION: Safety glasses should be worn at all times when working with vehicles and related tools and equipment.

86-95 Suzuki Samurai (89-04 Sidekick, X90, Tracker, Vitara & Grand Vitara) Warn Hubs (34581) SKU# SAX-WH

Installation Instructions

For additional copies of these and other instructions go to:www.lowrangeoffroad and click on the “Tech and Instructions” tab.

Suggested Tools:

• Twin Post Lift (or Floor Jack and (2) Jack Stands)

• Small Standard Screwdriver• Sockets: 10 & 12 mm• Socket: 4 mm Allen• Ratchet• Ball Peen Hammer - Medium• Snap Ring Pliers• Gasket Scraper• Torque Wrench - Foot-Pound• Torque Wrench - Inch-Pound

Step 1Lift and support the vehicle on a twin post lift.

Note: We used a twin post lift, but this job could easily be done with a floor jack and (2) safety stands.

Tech TipProper positioning of safety stands.

Tech TipProper positioning of twin post lift.

Front Support

Tech TipProper positioning of floor jack.

Rear Support

1. Wheel Stud2. Hub3. Spindle Nuts4. Locking Hub Gasket5. Locking Hub6. Locking Hub Cover Gasket7. C-Clip8. Locking Hub Cover Bolt9. Locking Hub Cover10. Locking Hub Bolt & Lock Washer11. Locking Hub Cone Washer

1

2

4

56

7

8

910

Hub Parts

3

11

Step 2 ContinuedLocking hub cover removed.

Step 2Remove the locking hub cover by removing the (6) bolts using a 10 mm socket.

Step 3Remove the C-Clip using snap ring pliers.

Note: This C-Clip can be discarded. It will not be used with these Premium Warn Hubs.

Step 4Remove the locking hub by removing the (6) locking hub bolts using 12 mm socket.

Removing the Hub Assembly

Step 5Once the bolts are removed, it may be necessary to tap the locking hub with a hammer to jar it loose.Note: This should not take much force. Tap gently!

Step 4 ContinuedEach bolt will have a lock washer and a cone washer.

Tech TipThis is a good time to check for looseness in the wheel bearings. To check for wheel bearing looseness, grab the top of the tire with one hand, the bottom of the tire with the other and alternate, pushing and pulling. If there is looseness felt in the hub, the wheel bearings need adjusting. Wheel bearing adjustment procedures can be found in our “Samurai Front Axle Knuckle Rebuild Instructions”. To access these instructions go to www.lowrangeoffroad.com and click on the “Tech and Instructions” tab.

Warn® Warranty Information“Verify that the spindle nuts are installed a n d t o r q u e d t o m a n u f a c t u r e ’ s specifications. Warn Locking Hub damage will occur if the spindle nuts or wheel bearings are loose! Damage to Warn Locking hubs due to loose spindle nuts or wheel bearings will void warranty!”

Click HERE for more about Warn Warranty information

Step 6Remove the Warn Hub from the box and remove the locking hub cover using a 4 mm allen socket.

Installing the Premium Warn Hub

Step 7Position the gasket on the New Warn® Locking Hub as shown.

Note: This gasket is not supplied with the Warn Hubs. It can be purchased from Subaru or you could use Permatex Ultra Grey Silicone Gasket Maker.

Step 8Remove the (6) cone washers by prying them open and sliding them off the bolts. Leave the lock washers in place and add the supplied flat washers in place of the cone washer. (See example in next step)

Step 9Align the holes in the Warn® Locking Hub with the holes in the vehicle hub. Install the (6) original bolts with the lock washer and supplied flat washers.

Flat Washer

Lock Washer

Step 10Progressively tighten the bolts in a criss-cross pattern ending at 18 - 25 ft. lbs.

Step 11Fit the supplied gasket on the locking hub cover.

Step 11 ContinuedInsure that the gasket fits the locating pin properly.

Locating Pin

Tech TipThese hubs are assembled at the factory with the proper type and amount of grease. No additional grease is needed.

Note: DO NOT PACK THESE HUBS WITH GREASE. THE HUBS WILL NOT FUNCTION PROPERLY.

Step 12Place the hub dial in the “FREE” or 4 X 2 position.

Step 13Orient the locking hub cover such that the locating pin fits in the correct groove.

Note: There are 3 separate grooves that the pin could be located in.

Groove

Locating Pin

Step 14Align the allen screw holes of the hub cover with the holes in the locking hub.

Step 15Start and snug the (6) allen screws finger tight using a 4 mm allen socket.

4 X 2

Step 16Torque these screws 45 to 55 INCH-POUNDS (This would be only 4 Foot-Pounds)

Note: If you do not have an Inch-Pound torque wrench, you can estimate these screws. 45 to 55 INCH-POUNDS is what we call “screwdriver” tight; but, no more than that. These screws are easily

Step 17Repeat Steps 2 through 16 on the driver side wheel.

Step 18Lower the vehicle to the floor.

Step 19Checking for Proper ENGAGEMENT1. Dial both hubs to “LOCK” or 4 X 4.2. Raise the front left wheel off the

ground and support the vehicle with a jack stand.

3. Spin the left tire.4. The front drive line should turn if the

hubs are locked properly.

Congratulation!You have successfully competed the job. If you have suggestions on how we could make these instructions or our products better, please let us know.

Step 20Checking for Proper DISENGAGEMENT1. Dial the left tire to “FREE” or 4 X 2

and spin the left tire.2. If the front drive line does not turn

AND there is no ratcheting sounds, the left hub is disengaged properly.

3. Repeat the Steps 19 & 20 on the right front wheel to check the right hub for proper operation.

As always, If you experience any difficulty during the installation of this product please contact Low Range Off-Road Technical Support at 801-805-6644 M-F 8am-5pm MST. Thank you for purchasing from Low Range Off-Road.

These instructions are designed as a general installation guide. Installation of many Low Range Off-Road products require specialized skills such as metal fabrication, welding and mechanical trouble shooting. If you have any questions or are unsure about how to proceed, please contact our shop at 801-805-6644 or seek help from a competent fabricator. Using fabrication tools such as welders, torches and grinders can cause serious bodily harm and death. Please operate equipment carefully and observe proper safety procedures.

Rock crawling and off-road driving are inherently dangerous activities. Some modifications will adversely affect the on-road handling characteristics of your vehicle. All products sold by Low Range Off-Road are sold for off road use only. Any other use or application is the responsibility of the purchaser and/or user. Some modifications and installation of certain aftermarket parts may under certain circumstances void your original dealer warranty. Modification of your vehicle may create dangerous conditions, which could cause roll-overs resulting in serious bodily injury or death. Buyers and users of these products hereby expressly assume all risks associated with any such modifications and use.

Revised 06/05/13© Copyright 2013 Low Range Off-Road, LC       All Rights Reserved