DISASSEMBLY & ASSEMBLY

1983–88 Monteros

1. Remove the front wheels of the vehicle, and support the raised front end of the vehicle with jackstands.
2. Set the control handles on the wheels to the FREE position, then remove the six hub cover retaining bolts. Remove the hub covers from the hubs.
3. Remove and discard the used hub cover gasket. A new gasket will be needed for reassembly.
4. Use snapring pliers to remove the snap ring on the end of the driveshaft. Slide the shim off of the end of the driveshaft.
5. Remove the front brake assembly, by unscrewing the two rear mounting bolts, with the hose connected. Use a wire to suspend the front brake assembly from the upper control arm so that the front brake assembly won't fall.

   WARNING
   Do not twist the brake hose.

6. Remove the six manual free-wheeling hub assembly mounting bolts, then slide the hub assembly off of the driveshaft.
7. Pull the free-wheeling hub clutch from the hub assembly.
8. Remove the compression spring, the follower and the tension spring.
9. Using a flat-tipped prytool, remove the snapring from the rear of the free-wheeling hub body. Remove the inner hub.
10. Remove the snapring from the inner hub with a pair of snapring pliers. Separate the free-wheeling hub ring, the spacer and the inner hub.

    Fig. 1: Front hub and manual free-wheeling hub assemblies' removal and installation — manual-change free-wheeling 4WD systems

    Fig. 2: Manual free-wheeling hub assembly disassembly and assembly components — manual-change free-wheeling 4WD systems

    Fig. 3: Apply the sealant to the shaded area in the illustration during the installation procedure — both 4WD systems (manual-change and automatic-change)

    To install:

11. Apply multipurpose grease (SAE J310, NLGI No. 2) to the entire periphery of the free-wheeling hub ring, the inner hub and the free-wheeling hub clutch, the free-wheeling hub cover and the inside of the free-wheeling hub body.
12. Check to be sure that the hub body assembly and hub cover assembly are coated with a sufficient coating of grease; add more grease if necessary.

    NOTE: A liberal amount of grease should be applied, especially when grease is wiped away or a new free-wheeling hub is installed.

13. Reassemble the spacer, the free-wheeling hub ring, the inner hub and the snapring. Slide the assembly into the rear of the free-wheeling hub body and secure it in place with the rear snapring.
14. To the rear of the free-wheeling hub cover, install the tension spring, the follower and the compression spring.
15. Slide the free-wheeling hub clutch into the hub body with any spacers that were removed.
16. Install the hub assembly onto the driveshaft. Apply a coating of 3M® ART Part No. 8661, No. 8663, or the equivalent, equally all around, to the free-wheeling hub body assembly and front hub contact surfaces. Tighten the mounting bolts to 36–43 ft. lbs. (50–60 Nm).

    NOTE: Make sure that there is no excess specified sealant on the hub outside surface.

17. Install the front shim and snap ring to the hub assembly.
18. Install the free-wheeling hub cover, with a new gasket, to the assembly. Tighten the mounting bolts to 7–10 ft. lbs. (10–14 Nm).
19. Install the wheels to the vehicle, then lower the vehicle to the ground. Tighten the lug nuts again.