Dana 44 Hub Rebuild
w/ Warn Hub Install

Axle Information: 1989 Jeep Grand Wagoneer Dana 44 front axle.
Instructions on how to rebuild, re-pack, and install Warn manual hubs. It is recommended that you read through these instructions before performing these tasks. Make sure this write-up is specific to your application. USE AT YOUR OWN RISK.
SAFETY FIRST Whether you're working on the axle on the vehicle or off - please make sure you take all necessary safety precautions before beginning any work. A clean and organized work area is beneficial. Make sure you have all the necessary parts on hand to complete the job. When removing parts, always lay them in an organized fashion so you can find the parts for re-assembly.
TEAR DOWN I When beginning to tear down - only do ONE SIDE AT A TIME. Never take both sides apart at once. Keep one side fully intact for a reference. Take off wheel, brake caliper, & hub cap off.
TEAR DOWN II Using snap ring pliers, remove the snap ring at the end of the shaft. Remove the "Drive Dog" out of the hub assembly. Using a magnet tool helps pull it out.
TEAR DOWN III Remove the outer spacer ring. Using the magnet tool again is very helpful.
TEAR DOWN IV Using a Hub Socket - remove the outer hub nut. Remove the lock washer (large washer with holes). Then remove the inner hub nut with the hub socket.
TEAR DOWN V The entire rotor and hub housing should easily come off and away from the axle. Be careful - the bearings are still inside the housing.
TEAR DOWN VI Remove the bearings out of the hub assembly - make sure you keep them separated (front or back). Remove the old seal. Save the old parts for reference (part numbers) for when you purchase replacements.
CLEANING It is very important that every part that is re-used (including bearings) are cleaned completely. During a complete rebuild - it is highly recommended to use a parts washer using proper solvents to remove all the old grease. It is very important NOT to combine grease!!!
INSPECTION After removing and cleaning your parts - inspect everything thoroughly to make sure you want to re-use. Inspect the spindle particularly where the bearings ride on. Inspect the rotor & hub assembly. Pay special attention to the outer bearing races that are located inside the hub housing. These bearing races should not be loose - they should be pressed in and tight. If they are loose, you can re-use them *see special note* below.
*Special Note* We discovered during our own rebuild - that the old bearing & outer races had worn away part of the hub housing. This is why the outer race was no longer a tight pressed fit. After installing everything, you can actually see the bearings turning AND the outer race turning which will further cause more wear on the hub housing. If this is not repaired - can cause further bearing failure, rotor (warping), and possibly spindle damage.
Parts You'll need to buy all the necessary parts to replace including bearing/hub grease, hub seal, bearings, and manual locking hubs (if applicable). We'll be installing Warn Premium manual locking hubs.


Backside of hub housing. This one was purchased brand new.
Using some rubber gloves (highly recommended) - place the required bearing grease in the palm of your hand. Hold onto the bearing with your other hand and begin pressing the grease into the bearing using the palm of your hand. Continue to do this until you've forced grease in around the entire bearing.
Insert the bearing on the backside of the hub housing. Add a small amount of grease around the area. It is not necessary to put a lot of grease here.
Carefully install the seal on the backside of the hub housing. You should use an object that is the same diameter as the seal and lightly tap the object with a mallet until it is seated properly (flush with outer edge) and evenly all the way around. we installed the bearing before the seal because you can't physically put the bearing in after the seal is installed.
Front Side of Hub Housing - Pack the bearing with grease the same way as you did previously. Work some grease inside this area around the splined sections.
Place the entire assembly on the spindle.
The inner hub nut will have a small pin sticking out of it. Make sure this pin is facing you. Install the hub nut - hand tighten.


Setting Bearing Pre-Load: Using the hub socket and a torque wrench (set at 50ft/lbs) Turn the rotor consistently and evenly while you slowly tighten the hub nut until you reach the required torque. It is important to spin the rotor while applying torque. After torque has been reached, back the nut OFF 1/4 turn.


The Round washer (with holes) has a square prong on the inside where it mates to the spindle. As you slide it on - you will also need to make sure the tiny pin on the inner hub nut goes into one of the holes. The washer should sit tight up against the hub nut. The hardest part is trying to get everything lined up properly. If you have trouble, remove the washer and flip it over.
Install the outer hub nut and tighten.
Slide the Drive Dog spacer in. This helps keep the Drive Dog or drive mechanism spaced properly.

Original Hubs? - Install the Drive Dog gear back in place at this time.

Warn Manual Hubs? Install the drive mechanism (as seen) and refer to your WARN installation instructions.

Other Manual Hubs? Refer to your installation instructions at this time.

After setting the drive mechanism in place, install the snap ring ensuring that it is sitting properly in the grove on the axle shaft.

Drive Dog?? Install the snap ring in a similar fashion.

Install the big round snap ring as stated in the WARN instructions. There should be a grove on the hub assembly this ring should snap into place.

Install manual locking hub outer switch mechanism (be careful with this - there is a small o-ring on the outside that prevents water from getting in). Install Allen bolts and tighten in a star fashion.

Drive Dog? Install the outer hub cap applying some RTV sealant to the cap flat edge. This will help prevent water from getting inside your hub housing.

Test your manual hubs -turn the rotor by hand and switch the mechanism to make sure it is functional and nothing is binding. Install your caliper components & tires and go for a ride!! For the next several days or weeks - be sensitive to noises or smells. Place your hand on the hub to feel for excessive heat. You should be able to touch it and leave you hand there.