Manual Hub Clutch Assembly
I installed AISIN Manual Hubs on the Trooper. With Manual Hubs I can disconnect the front drivetrain from the wheels. This will result in less wear and tear on all the front drive train components, and should result in better fuel economy on the street.
(The broken stud will be replaced soon)
There is an article on how to change from fixed hubs to Manual Hubs on 4x4Wire . From what I have been told you can do this swap up to 97, but not on 98 or later versions.
The tools you need are: jack, jackstands 10mm socket, 8mm internal wrenching socket (Allen socket), 4" extension and ratchet for the sockets, can of brake cleaner, tube of RTF silicone, circlip pliers, and a torque wrench.
The way I did the swap differed slightly from the method described in the 4x4Wire article. I used an 8mm internal wrenching socket, so that I could get the proper torque on the Allen bolts when I tightened them. I also found out that you do not have to remove the wheel to do the swap. I removed the drivers side wheel to do the swap, and did not remove the passenger side wheel to do the swap. It didn't seem to make a difference one way or the other.
If you bought used AISIN hubs from a salvage yard, like I did, the clutch may be in pieces. Putting it back together is not difficult, but not necessarily intuitive. The parts go together in the sequence shown in this photo.
Clutch, Follower and Spring, Spring, Knob
The Brass colored piece is called the follower. It is connected to the clutch via a spring that nests in side it. That spring is retained by tabs on the follower that prevent the spring from rotating and from falling out of the follower. The purpose of this spring is to pull the clutch off the axle splines when the hub is in the freewheeling mode. This photo shows how the bent end of the spring and it's orientation to the tab that keeps it from rotating.
There are tabs inside the follower that hold the spring to the follower
A portion of that spring fits in a groove that is cut 1/2 way around the clutch. This shows the groove in the clutch.
This portion of the spring fits in the groove shown above
When the follower, spring and clutch are assembled, it should look like this.
On the knob are the grooves and ramps that enable the clutch assembly to engage and disengage the axle.
Once the clutch is assembled, the large spring is set over the inside portion of the knob. You can see the portion of the follower that goes into the knobs grooves.
Then compress the spring with the clutch assembly aligning the tabs of the follower with the grooves.
Once the tabs are below the tabs on the knob rotate the clutch assembly counter clockwise, until the tabs on the follower are past the tabs on the knob. The knob/clutch assembly is now complete.
Rotate the knob in the housing to the Free position. That will pull the clutch assembly closer to the knob. It is now ready to install on the vehicle.
There are 10 grooves cut inside the body of the hub 2 of those grooves are noticeably wider than the others. Those wide grooves are meant to accommodate the 2 of the tabs on the follower. When inserting the knob/clutch assembly into the body make sure that the tabs on the follower align with the wide grooves of the body.