I just finished swapping 87 Grand Wagoneer axles under my 95 YJ. Well, not quite finished - waiting for my fabricator friend to come over and weld the rear perches. Anyway, the fronts done, and I installed my new warn premium hubs, so......
Hope this helps:
When I disassembled mine, behind the dust cap there was a c clip holding the drive flange (solid hub), a spring (single, same diameter has the hub), then the locking washers for the wheel bearings. It's possible that there was a washer between the spring and the wheel nuts, not really sure.
Anyway, I simply went to a local parts store and bought Warn premium internal hubs for a dana 44. Apparently they are all the same. What you do is reinstall the rotor/hub, install the wheel bearings nuts as per usual, then replace EVERYTHING else outboard of the wheel nuts with the warn hub. So although it sounds like your stock hubs were incorrectly installed, all you need to install new hubs is the wheel nuts and locking washers (that go between the 2 wheel nuts). The rest gets chucked. The only special tool you need is the Dana 44 wheel bearing nut tool.
The internal hub body slides right into the rotor/hub (sorry I don;t know the proper technical term for this part), then a big snap ring goes in to hold that in place. You push the axle out as far as it will go and you can install the snap ring on the end of the axle shaft that holds the warn hub body in place. There is meant to be some axle sticking out of the spindle - that's where the clip goes to hold the hub in. Won't cause any problems.
you then line up the warn hub outer cap with one of the screws, screw in the allen head screws (requires 7/64 hex head, I think. email me if you don't have a complete set and want to know the exact size and I will check for you), and you are done!
I was amazed by how simple a process it was, and how easily and well the warn hubs went into place and work. And I now have real, internal, locking hubs! Real cool! I was also a little worried about it originally because I ended up with a basket of parts when I disassembled it, and wasn;t sure if I could remember where everything went. because the hubs replace everything outboard of the bearing nuts, you don;t really need to worry about the rest.
email me if you want more info. I don't hit the boards that often, so if you need more answers right away, best to email me at
[email protected]