Outer Limits 4x4 Board

Hi all,

I'm stuck at the final stage of my front diff rebuild - putting the free wheel hubs back together. I have just put a spartan locker in the front of my 80 series and am dumbfounded as to how the free wheel hub assembly goes back together - I've followed the instructions in the Toyota workshop manual, but it seems it does not in fact disengage.

I can turn the hub from free to locked as per normal, so all the teeth and the springs are lined up, but weirdly, I cannot spin the wheel, even when the hub is in "free" mode. WTF am I missing...?!?!

did you use a truckload of grease in the freewheel hub? if so this can stop it from disengaging, it just sucks back onto the gears. scott

I've seen this firsthand, my mates surf drove all the way to Indian head (fraser), loaded trailer, no 4wd!

Too much grease in the free wheeling hub, scoup out grease (as everyone, including police!, looks on taking the piss), bolt back on, and off she went!

so we put it all back together, it seems there is nothing that actually disengages the FWH from the axle - I guess just the spinning force makes it come undone... very weird, but the problem has been solved (I guess)...

De-lux wrote:so we put it all back together, it seems there is nothing that actually disengages the FWH from the axle - I guess just the spinning force makes it come undone... very weird, but the problem has been solved (I guess)...

Then it's been done wrong. The cam on the engagement wheel is what forces it back into engagement, and the return spring pulls it back when reversed. Surely someone in this guys' area can spare a hour to go show him how it's done?

Check this vid out http://www.youtube.com/watch?v=dxSBcAyt2WA" onclick="window.open(this.href);return false;

Forget the Longfeild replacement part, but the rest of it will show you how they go together

I did watch that video.. thanks Zoltan. Below is an extract from the workshop manual - I have circled in red the parts that I am not comprehending.

How does the spring-pawl-spring attach to the clutch to pull it out (i.e. disengage)?

I should clarify further... I know that the small spring is threaded into the clutch, but to be more specific, how does the pawl attach to the small spring to pull it out? As far as I can comprehend, the pawl just sits on the small spring. I'm not sure I am being clear enough...

De-lux wrote:I should clarify further... I know that the small spring is threaded into the clutch, but to be more specific, how does the pawl attach to the small spring to pull it out? As far as I can comprehend, the pawl just sits on the small spring. I'm not sure I am being clear enough...

the tightly wound spring is wound into BOTH the lock sleeve AND one wrap sits under the pawl so that it holds the pawl to the sleeve. then the bent tongues on the pawl latch under the ramps on the turning mechanism and that is what pulls it back