Locking Hub - Manual

This procedure covers the removal and installation of manual locking hubs on a 4WD Dodge Ram 2500 with the 5.9L Cummins diesel engine, including axle nut removal and hub assembly replacement.

Warnings

Tools required

Parts

• Manual locking hub assembly × 2 — OEM or aftermarket (Warn, Mile Marker)
• Axle nut cotter pin × 2 — Use OEM specification
• Hub cover gasket or O-ring (if applicable) × 2 — Included with hub assembly
• Anti-seize compound × 1 — High-temp nickel or copper

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Shift transfer case to 2WD position
4. Turn manual locking hubs to 'FREE' or unlocked position
5. Loosen front wheel lug nuts while vehicle is on ground

Procedure

1. 1

   Lift and secure vehicle
   Raise the front of the vehicle using a floor jack at the front axle differential housing. Support the vehicle with jack stands placed under the frame rails. Remove both front wheels completely.
2. 2

   Remove locking hub cover
   Remove the external cover screws (typically 6 screws) from the manual locking hub assembly using the appropriate socket. Carefully pull the hub cover assembly straight off the wheel hub. If stuck, gently tap around the perimeter with a rubber mallet. Note the position of any alignment marks or tabs.
3. 3

   Remove cotter pin and axle nut
   Remove the cotter pin from the axle nut using cotter pin pliers or needle nose pliers. If the nut is staked instead of pinned, use a punch to unstake it. Use a 36mm socket and breaker bar to remove the axle nut. This requires significant force. Do not reuse the cotter pin.
   ⚠Have an assistant apply brake pedal pressure or use a pry bar against wheel studs to prevent hub rotation while loosening axle nut
4. 4

   Remove snap ring and hub body
   Locate the snap ring that retains the hub body to the spindle. Use snap ring pliers to remove this retaining ring. Once removed, pull the manual locking hub body straight off the axle shaft. The hub mechanism should come off as a complete assembly. Note the position of any spring-loaded components.
5. 5

   Inspect axle shaft and splines
   With the hub removed, inspect the axle shaft splines for wear, damage, or corrosion. Check the wheel bearing adjustment by attempting to move the rotor/hub assembly in and out on the spindle. There should be minimal play. Clean the axle shaft threads and splines thoroughly with a wire brush and solvent. Remove all old grease and debris.
6. 6

   Prepare new locking hub assembly
   Unpack the new manual locking hub assembly and verify all components are included. Ensure the hub is set to the 'FREE' or unlocked position. If the assembly includes a gasket or O-ring, install it onto the back of the hub body. Apply a light coating of anti-seize compound to the axle shaft splines (not the threads).
7. 7

   Install hub body and snap ring
   Align the splines of the new manual locking hub with the axle shaft splines. Slide the hub body straight onto the axle shaft, ensuring it seats fully against the wheel hub face. Install the snap ring into its groove on the spindle using snap ring pliers. Verify the snap ring is fully seated in its groove all the way around.
8. 8

   Install and torque axle nut
   Thread the axle nut onto the axle shaft by hand to ensure proper thread engagement. Use a 36mm socket and torque wrench to tighten the axle nut to specification. Have an assistant apply brake pressure or use a pry bar to prevent rotation during tightening. Install a new cotter pin through the axle nut and shaft, or stake the nut per manufacturer specifications. Bend cotter pin ends to secure.
   ⚠Never reuse the old cotter pin; always install a new one to ensure proper retention
9. 9

   Install hub cover assembly
   Position the external hub cover over the locking hub body, aligning any tabs or alignment marks noted during disassembly. Ensure the cover is fully seated and flush against the hub body. Install all cover screws and hand-tighten them first. Torque the screws in a star pattern to the specified torque to ensure even pressure distribution.
10. 10

    Reinstall wheels and lower vehicle
    Install the front wheels, threading lug nuts by hand first. Lower the vehicle until the tires just touch the ground but still have minimal weight on them. Torque the wheel lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands.

Reassembly

1. Repeat the entire procedure for the opposite side locking hub
2. Test both manual locking hubs by rotating the external dial from 'FREE' to 'LOCK' and verifying smooth operation
3. Ensure no fasteners or tools were left in the wheel well area

Verification

• With the transfer case in 2WD and hubs in 'FREE' position, verify the front wheels spin freely when lifted off the ground
• Engage transfer case to 4WD and manually lock both hubs to 'LOCK' position
• Drive the vehicle forward and reverse slowly to verify 4WD engagement and proper hub operation
• Check for any unusual noises or vibrations from the front hubs during a short test drive
• Re-torque wheel lug nuts after 50-100 miles of driving

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