Keep the bearings tight

On earlier versions of the Warn Full-Floater, I've found that the bearings tend to loosen up after just a few runs unless you are careful to note certain characteristics of the spindle and how the washers are installed. Later versions have solved this problem by increasing the length and depth of the spindle groove, increasing the length of the threads and using hardened washers. However, if you have experienced bearing loosening on yours, you might want to read further.

Here's the bearing slipped on the spindle with the tanged washer as close to it as the original groove will allow. When the bearing is slipped all the way to the stop on the spindle, the washer can be installed snug against it. In order for the washer to slide all the way to the bearing, the groove in the spindle must extend far enough toward the bearing for this to happen. I noticed that my washers, on wheels where bearings loosened up, got bevels in them where the tang of the washer was hitting the end of the groove.

See the bevel on the tang on the washer? They don't come this way. That bevel gets there when you tighten the inner nut on the spindle and that forces the washer into what is remaining in the spindle groove. This means you are not putting the right amount of pre-load on your bearing, which can then loosen up.

Here, I'm carefully grinding a longer notch in the spindle groove so the washer can go tight against the bearing without the washer tang hitting the spindle first. Take care to keep the notch no deeper than it takes to slip the washer on to it.

Here is the same washer and bearing with the washer in the extended groove snub against the bearing. You don't know if the bearing will go all the way to where it is now once your wheel hub is installed, however it may. Doing this assures you that, when you tighten the inner axle nut, you will be putting the correct amount of pressure on your bearing instead of just deforming the inner washer.

If you have the later version of the Full-Floater, you may not be having this problem. You might want to check out that washer and groove next time you have the wheel hub off.

Following are some misc. photos of the spindles, showing the shallow groove on the rears and and the deeper groove on a stock front spindle. Also shows how the pilot diameter (abt 3 3/8") on the portion that inserts into my particular rear axle matches the pilot diameter on my stock (Dana 44) front axle. This way, I can carry one extra rear spindle that can be used to get me home if any one of the spindles goes amiss.

Shallow groove on left, deeper and longer grove on rightt. ..........Diameter of stock front is abt 3 3/8"

Rear Spindle pilot dia, abt. 3 3/8"................................................Newer rear and older front spindles

Warn is now supplying spindles with longer and deeper grooves. The rear shown is an earlier version prior to my lengenthing the groove. Looking closely at it, you can see that the bearing surface has been hammered by loose bearings. The old one is also a throwaway, but we are keeping them as an emergency spares.

Tip...When driving long distances or flat-towing, make it a habit to feel how warm the hubs are getting. If you find one getting warmer than the rest, you probably have a bad bearing which will lead to failure, often wiping out the spindle also. This is especially important if you have been in muck or doing water crossings.

Happy Trails,

Jim Piatt