Locking hub won't go into hub?!?

[swanthog]

I bought a new Warn locking for my 1980 3/4 ton and it won't go into the hub. I double checked that the correct Warn was purchased and should fit but it's not going in there. No way.

The outside diameter of the Warn is slightly larger than the hub opening. The outer and inner splines line up and it will slide in until the larger diameter part of the Warn is reached.

Has anyway encountered this before? Could the hub be warped to the point that the locker no longer fits? It doesn't appear to be damaged.
Is it possible that someone put a different year-range hub that requires a different Warn locker?

Thanks,
Lawrence F.

[Front Range]

Measuring a loose Warn hub lock knob I get 3 1/8" width for both the cap end and the guts.

Measuring a loose hub I also get 3 1/8" inner dimension on the end where the lock seats.

[russgt]

I bought some replacement rotors and hubs from Autozone a few years ago for my 76 K5 and had the same issue. My stock spicer lockouts were slightly larger than the splined opening in the replacement hubs.

[swanthog]

Sure enough. Warner locker is 3.125" and inside of hub is ~3.110".
This is really a pisser since I just installed new Rotor, bearings, races, and a seal along with the new locker.
One thing I am considering doing is shaving some of the aluminum off the outer surface of the locker. It is only about 1/64" off the circumference (unless I got my math wrong). It doesn't seem like much but it is enough to prevent the locker from being installed.
This seems like a harmless thing to do since the functional areas of the locker -- inner and outer splines and height or distance locker extends into hub -- will be unchanged. Thoughts?

Thanks you all for your responses so far.

--Lawrence F.

[cadillac_al]

I don't see how this could be happening. I thought all 1/2 & 3/4 ton hubs were the same. I wonder what changed?

[swanthog]

I think it's like RUSSGT mentioned, cheap replacement hubs are to blame.
Either that or someone swapped in one from a different year range or manufacturer or ... who knows. I don't even know if it's possible but these Dana 44 setups are on a lot of makes.

I found a Wagner replacement hub from Jegs:
http://www.jegs.com/i/Wagner/436/BD61708/10002/-1

Does anyone have any experience with these?

Thanks,
Lawrence F.

[cadillac_al]

I would be inclined to send them back and try another set. They are either defective or the wrong ones. I haven't had to mess with any hubs on my D44's because they are full time and I have Mile Marker hubs on my D60 and they seem to be very good quality.

[swanthog]

cadillac_al, I had that same setup on my '77 Silverado K20 fleetside. I do miss that truck.

So, I took down the outside diameter of the locker on the bench grinder, carefully rotating while attempting to keep everything square and use even pressure. I moved really slowly and finally whittled it down to a size that fits after 6-7 passes. It's all bolted together now and working as it should.





Thanks everyone for your time and advice.

--Lawrence F.