Installation Instructions for DYNATRAC Conversion Kits
KLM PERFORMANCE IS THE EAST COAST DISTRIBUTOR FOR DYNATRAC
FREE SPIN HUB KITS. KLM PERFORMANCE HAS ALL DYNATRAC FREE SPIN HUB KITS IN
STOCK. NEED THE KIT TODAY? CALL US BY 3:00 P.M. AND IT WILL SHIP TODAY. WE DON'T
DROP SHIP.
WE SHIP FROM
OUR INVENTORY.
IF YOUR TRUCK IS DOWN AND YOU NEED
THE KIT NOW, CALL KLM PERFORMANCE.
Dynatrac hubs are a world apart. Click here to
read more and for comparison pictures
showing the difference between OEM hubs and Dynatrac hubs. Many people who appear to be using their trucks under normal conditions --
stock tires and light-duty use -- have experienced failures within the first
50,000 miles of ownership. Officially, Ford says the unit bearings are a "nornal
wear" item, and therefore not covered by warranty at any mileage level.
Furthermore, some dealers are approving the work under warranty on a case-by
case basis. One-time repairs at a dealership can easily exceed $1,500. Fortunately, there is now a fix.
Installation Instructions for Dynatrac Hub Conversion Kits
2000-2007 Dodge Hub Kit Stage 1 4x4, Front Axle Free Spin
Conversion Kit
Some of the less
common tools, which will be required:
ท
6-point Spanner socket (OTC
#7090-A or equivalent) OR 4-point Spanner socket (OTC #7158 or
equivalent). These can be purchased from Dynatrac or an auto parts store.
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14mm, 12-point, ฝ drive socket
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1-11/16, 6 point socket
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Calibrated torque wrench.
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Anti-Seize compound.
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High quality, disc brake wheel
bearing grease.
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Bearing Race Punch (Snap-on
#PPC14LA is a good one) to install bearing races.
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4 quarts of high quality gear oil
- OPTIONAL
Preparation and Inspection Checks:
1.
Read all instructions completely. Only perform this installation if you
are an experienced, fully equipped mechanic. Inspect all boxes and packing
material to expose all the parts in the kit. Using the bill of material
attached, verify that the kit is complete. Contact Dynatrac about any shortages
at (714) 596-4461. Do not start the installation until you are sure you have
everything you need. Allow yourself plenty of time. You will need anywhere from
5 to 10 hours depending on your skill and experience level.
WARNING: Always wear proper safety
equipment including safety glasses and gloves while working with tools.
Improper use of tools and equipment can cause injury or death.
WARNING: Only perform this installation if
you are an experienced, fully equipped mechanic.
2.
You can reuse the original U-joints, but it is a good idea to replace the
U-joints when installing this kit. We have designed it to work with your
original parts. Use caution not to damage your U-joints when removing them from
the outer axle shaft. If you do need a U-joint for this application, and you
have a 03 & newer truck (with AAM axle), the joints are currently available
only through your Dodge Dealer. So, check for availability before you take your
truck apart. If you have a 00-02 truck (Dana 60 axle), the U-joints are common
at most auto parts stores, and are in stock at Dynatrac.
iINFORMATION:
Replace old U-Joints if they are worn.
WARNING: If tone rings are not installed
on your hubs, the ABS system will not work.
3.
If your truck is ABS equipped, make sure the new hubs have tone rings
mounted on the short side of the new hubs. See Illustration 1. If
they have been shipped loose they should lightly press onto the back of the hub.
Tapping them on with a soft face, dead blow hammer works fine.
4.
Inspect the inside of the new wheel hubs for any leftover debris or dirt.
Wash the inside thoroughly with rags and hot soapy water. If the bearing races
are not already installed in the wheel hubs, use a race driver to install them
at this time. Snap-on, 9/16 race driver, #PPC14LA works great.
5.
Test fit the new inner and outer bearings onto each of the new spindles.
The bearings will fit snug, but go on easily by hand. However, it is a very
precise fit. If they get cocked they will lock themselves into place. Tapping
them lightly on the high side will straighten them out. Patience is essential.
6.
Drive or press new wheel studs supplied with the kit into the new wheel
hubs at this time. The new studs should go in very tight and be fully seated.
The studs should not stick up above the counter bore in the hub flange.
WARNING: DO NOT pull the studs through
with a lug nut, as this will risk your safety and the safety of those around you
on the highway. Improperly installed studs can cause major failures that could
lead to injury or death.
7.
Raise the front axle off the ground and secure with jack stands. Remove
the wheels.
WARNING: Always use appropriate jack
stands when raising your vehicle. Never work under a vehicle that is not
properly secured. Be sure to chock any wheels that are on the ground.
Begin Front Axle
Teardown:
8.
You may wish to remove the differential cover and drain the gear oil. It
is common for oil to leak into the axle housing tubes when the inner axles are
pulled outward past the inner axle seals. Whether you drain the oil or not, it
is best to thoroughly clean the inside of the axle tubes from any dirt, rust or
oil residue BEFORE re-installing the axle shafts later in the install process.
9.
Using the 1-11/16 socket and a long breaker bar (or impact gun), remove
the cotter pin and the big nut at the center of
the stock live spindle assembly. The nut can be very tight. Have someone step on
the brake pedal to keep the stock hub from rotating if needed.
10.
Remove the calipers and hang them securely from the frame without
disconnecting the brake hoses. Remove the rotors.
11.
There are two (2) pilot diameters
machined on the outer end (long side) of the new wheel hubs. The inner pilot
(larger diameter) locates the rotor and the smaller outer pilot locates the
wheel. Make sure that the rotor and the wheel fit easily but snugly around their
respective pilot diameter.
iINFORMATION:
Trial fit all parts on both sides of the truck before assembly.
12.
If truck is equipped with front
ABS: Remove the sensor and cable from
the unit bearing. It is held in with only one (1) screw, and pulls straight out.
Tie off and out of the way. At this time make certain that the hubs included in
the kit have ABS tone rings pressed on to the short side of the hub. If the hubs
do not have the tone rings, contact Dynatrac immediately for replacements.
WARNING: If tone rings are not installed
on your hubs, the ABS system will not work.
CAUTION: Be careful not to damage the ABS
sensor while removing it from the unit bearing.
13.
To remove the unit bearing assembly: Use
ONLY a 14mm 12 point socket to remove the 4 bolts that hold the live
spindle assembly to the knuckle. Other sockets may appear to fit, but may cause
the bolt heads to become rounded off!! They are removed from the backside. Set
aside unit bearing and the brake shield. Keep the four (4) bolts for installing
the new spindle.
WARNING: Do not use high heat to
remove the live spindle from the knuckle, this can cause damage to the
components and reduce their strength.
14.
FOR 00-02 trucks only:
Your truck is equipped with an axle disconnect mechanism in the RH axle tube.
Remove the vacuum motor from the disconnect housing mid-way on the RH tube.
Inside will be a splined collar. Note how it mates with the axle shafts inside.
These parts must be re-installed when the RH axle shaft in assembled later in
the install process.
15.
Remove the axle shaft assembly. It is only held in by tight seal tension
at the differential. Use 1 or 2 pry bars between the yoke and the end of the
axle housing to pull straight outward if necessary. Be careful not to damage
your axle seals when removing the shafts. Set shafts aside.
16.
Remove the stock outer shafts from the U-joints. The U-joint caps are
matched to the U-joint so make sure that they are put back in the right
locations. Install the new 35 spline outer shaft onto the U-joint. If
you have a 2003 & newer truck (AAM axle), you will need to use two (2) U-Joint
Shims. The U-joint shims are to be installed between the inner ears of the
outer shaft and the snap ring on the U-joint. See Illustration 2.
00-02 trucks DO NOT use the shims. If the old joints are worn out, this is
the best time to replace them. If you need a U-joint, and you have an 03 &
newer (with AAM axle) truck the joints are currently available only through your
Dodge Dealer. So, check for availability before you take your truck apart. If
you have a 00-02 (Dana 60 axle) truck, the U-joints are common at most auto
parts stores, and are in stock at Dynatrac.
iINFORMATION:
Replace old U-Joints if they appear worn.
Begin Front Axle
Reassembly:
17.
Install the boot seals on the outer shafts. They should press onto the
shoulder of the outer shaft with the force of your hands. See Illustration
2.
18.
If you have not cleaned the inside of the axle tubes as discussed in Step
7. Do so at this time.
19.
If not already assembled, place the spindle back spacer in the back of
the spindle with a light coating of anti-seize compound. The anti-seize will
make any future servicing much easier. See Illustration 2. When
installed correctly the needle bearing should be ผ below the surface of the
back-spacer/spindle. This leave enough room for the thrustwasher/seal assembly
to also be pressed in to place. DO NOT install the thrustwasher/seal
until you tighten the screws that hold the backspacer in place (next 2 steps)
20.
If not already assembled, install the four (4) ผ - 20 x .75 socket head
cap screws with Loc-tite 271, but do not tighten. Press the spindle bearing
into the back spacer and spindle; this will align the spacer in the back pocket
of the spindle. Torque the screws to15 ft-lbs.
21.
Test fit your outer shafts fully into the needle bearing in the back of
the spindle. It should go in completely, easily and rotate freely. If it is
tight, or does not rotate easily contact Dynatrac for a replacement. Be careful
not to damage the spindle seal (if already installed) with the splines when
installing the shaft.
22.
If not already installed, press the thrust washer and seal assembly into
the spindle back spacer. The thrust washer must snap onto the seal housing. It
will only snap on one way.
23.
Coat the seal surfaces on the inner shafts lightly with grease at the end
of the shaft that is going into the differential.
24.
FOR 00-02 trucks only:
Your truck is equipped with an axle disconnect mechanism in the RH axle tube.
Make sure the spline collar discussed in Step 14, is in its proper place
inside the disconnect housing. The collar must easily slide back and forth over
the large splines on the inner RH shaft (never removed) and the middle RH shaft,
which should now have the new 35-spline shaft mounted to it.
25.
Carefully insert the shaft into the axle housing. Be careful not to get
any dirt or other contamination on the shaft as you install it, as it could
damage the bearings and seals. Guide the shaft up into the inner seal and
differential gears. Use a rubber mallet to tap the end of the shaft inward until
it stops. You may have to rotate the shaft to align the splines in the
differential.
26.
Fill the boot seal on the outer shaft with high quality wheel bearing
grease. Coat the area around the thrust washer with grease. Also add some
grease to the spindle needle bearing.
27.
Install the brake splash shields for the front disc brakes between the
spindle and the knuckle. Make sure they are not on backwards, or the shield will
not allow the rotor to be installed.
28.
Put a light coating of anti-seize compound on the shoulder surface of the
spindle. The anti-seize will make any future servicing much easier. While
guiding the outer shaft through the spindle, mount the spindle into the knuckle;
be careful not to damage the seal in the back of the spindle. Position the ABS
sensor block at the 12 oclock position.
29.
Reuse your four (4) spindle mounting bolts (9/16-18 x 1.25) to secure
the spindle to the knuckle. Apply Lock-tite 271 to the bolts. Tighten the
bolts to 85 ft-lbs in a criss-cross pattern. Make sure the spindle is firmly
seated and there are no gaps between the knuckle, shield, or spindle.
WARNING: Use a calibrated torque wrench on
all bolts. Always torque bolts in the order listed.
30.
Check the shaft assembly for some endplay in and out. There MUST
be at least some endplay. The grease may make it difficult to feel the end play,
so you may want to pry the shaft in and out several times using screwdrivers at
the U-joint until you are certain that end play is present. DO NOT CONTINUE IF
THERE IS NO END PLAY. Also look inside the disconnect housing. Make sure the
seal is riding on the axle shaft seal surface of the RH mid-shaft.
WARNING: Do not continue if there is no
endplay in the shaft assembly after installation. Contact Dynatrac for
assistance.
31.
Pack the new wheel bearings with grease. Proper packing of the bearings
is essential to bearing life and safety. Grease must throughly and completely
fill the voids between each roller, especially underneath the roller cage.
Do not just smear grease around the outside. This can easily be accomplished by
hand or with a simple bearing packer and grease gun available at any auto parts
store. If you are not sure how to pack a bearing by hand, Dynatrac can
provide a one page guide written by Timken via Fax, Email, or USMail on request.
Load the inner bearing (large) into the new hub and drive the hub seal into the
back of the hub. The open side of the seal faces the inside of the hub.Use your
finger to also fill the area between the lips of the seal with grease.
WARNING: Properly packing the wheel
bearings is essential to bearing life. Failure to properly lubricate a bearing
can result in bearing failure, damage to other components, and risk of serious
injury or death.
32.
On the new hubs, completely fill the area inside the hub, between the
bearings with grease up to the inside diameter of the inner & outer bearings.
Dont skimp on the grease. There must be enough grease between the bearings so
that centrifugal force does not pull grease away from the bearings into the
center of the hub.
33.
After fully packing with grease, install the new wheel hubs onto the
spindles. Be careful not to damage the hub seal as it slides over the threaded
end of the spindle. Push the hub onto the spindle until the inner bearing
bottoms out. If it gets stuck part way, stop! Pull the hub off and try
again, keeping the bearing straight as it slides onto the spindle. Push the
outer bearing over the end of the spindle and into the open end of the hub. It
must seat against the outer race in the wheel hub.
CAUTION: Be careful not to damage the hub
seal when installing it over the threaded end of the spindle.
WARNING: Do not use the spanner nuts to
force the hub and bearings onto the spindle. If necessary, you may gently use a
rubber mallet to tap the outer edge of the hub.
34.
Screw the inner spanner nut onto the end of the spindle. There are
two (2) types of spanner nut sets, 4-point & 6-point. On the 6-point style the
inner and outer nuts are identical. On the 4-point style, the inner nut has a
tiny pin which must face outward. Torque the inner nut to 50 ft.lbs while
rotating the hub. Then back off the inner nut approximately 1/8
to ผ of a turn. See page 1 for sourcing the proper hub socket. DO NOT use
punches to tap the nuts around!
WARNING: When installing a 4-point style
spanner nut, the inner nut pin MUST face outward.
WARNING: Use the proper tools and
procedure to install the spanner nuts or you may damage the bearings.
35.
For 4-point spanner nuts only:
Align the pin on the inner nut with a hole in the lock washer. The tab on the
inside of the lock washer must align with the slot in the spindle at the same
time. Be careful not to tighten or loosen the inner nut too much to achieve
alignment. The hub should spin freely with no pre-load on the bearings, but not
have more than .001 of end play. Only after the washer is fully seated against
the inner nut, may you screw on the outer nut (has no pin). Tighten the outer
nut to 70-75 ft-lbs.
36.
For 6-point spanner nuts only:
Install the star shaped lock washer with the outer tabs pointing outward. Align
the tab on the inside of the washer with the slot in the spindle. Put a coat of
grease on the back of the outer spanner nut. Screw the outer spanner nut on the
spindle and tighten to 65-70 ft-lbs. Then bend at least one of the tabs over the
front of the outer nut into one of the six (6) points on the nut. The hub
should spin freely with no pre-load on the bearings, but not have more than
.001 of end play.
37.
Install the WARNา
premium locking hubs. The gear body just slides in, and is held in place by the
big internal snap ring. Then the small snap ring goes over the end of the outer
axle shaft. You may need to pry the axle shaft outward to expose the snap ring
groove on the end of the shaft.
38.
Six (6) Allen screws hold on the cap. DO NOT over tighten the Allen
screws. Further instructions are included with the locking hubs. Please refer
to those directions for installing your hubs.
39.
Check the hubs by locking and unlocking several times. Never use tools to
turn the locking hub knobs; they should turn without the use of a tool. Rotate
the wheel forward and backward while simultaneously turning the knob if you feel
too much resistance.
CAUTION: Further instructions are included
with the WARNา
locking hubs; follow them for proper installation.
CAUTION: Never use tools to turn the knob
on the locking hub; it should turn without the use of a tool.
40.
ABS Equipped Only:
Insert the ABS Sensor into the mounting block on the spindle. Use the stock
screw to secure it. There should be an air gap between the tone ring and the tip
of the sensor of at least .015 but less than .055. Secure the ABS sensor
wiring as it was before you removed it from the original unit bearing so that it
is clear of all moving components.
WARNING: Make sure that the ABS sensor has
at least .015 clearance between the tip of the sensor and the tone ring. If
the ABS sensor contacts the tone ring it can be damaged resulting in the ABS
system to malfunction.
41.
Install the stock brake rotor over the outside of the wheel hub and hold
it in place with two (2) lug nuts. Route the cable for the ABS sensor so it will
NOT touch the inside of the rotor during vehicle operation. Rotate the rotor
360ฐ
to make sure that there is no interference with any other components.
WARNING: Make sure that the ABS sensor
cable is secure and clear of the rotor.
42.
Put the caliper back over the rotor and secure using your original
caliper bolts with some Lock-tite 271. Tighten bolts to factory specifications.
Spin the rotor and make certain that the caliper has adequate clearance from the
brake rotor.
WARNING: Reinstall the large bolts that hold
the caliper to the ears on the knuckle. Check for adequate clearance between the
brake rotor and the caliper.
43.
FOR 00-02 trucks only:
Your truck is equipped with an axle disconnect mechanism in the RH axle tube.
Use silicone to seal and reinstall the vacuum motor on the disconnect housing.
Make sure the fork engages the slot on the outside of the collar.
44.
Install your wheels on the new hubs and tighten your lug nuts to 110
ft-lbs.
45.
If any gear oil was lost during installation of your hub kit, refill the
axle to the previously noted level and test drive.
WARNING: Failure to properly refill the
axle with Gear Oil can cause serious gear and bearing failure which could result
in serious injury or death.
46.
Recheck bolt torque on lug nuts after test-driving.
47.
Verify the proper gear oil level after a test drive.
48.
Check the torque on your lug nuts every 500 miles.
WARNING: Failure to check bolt and lugnut
torque can cause serious accident, component failure, serious injury or death.
Bill of Material
About
Dynatrac and Dynatrac Hubs
For over 15 years, Dynatrac has been
the industry leader in high performance axle and drive
train assemblies. Dynatrac's products are designed using
the finest materials, processes, and engineering
available. Plus, Dynatrac proudly manufactures each
component in the United States and back its products
with the best service and warranty in the business. No
matter what type of vehicle you have or driving you do,
Dynatrac Products put the confidence underneath you to
get the job done, saving you time, money and headaches.
Dynatrac was founded to provide
off-road enthusiasts, small businesses, and corporate
fleets with a dependable source for high-quality drive
axle equipment. By offering the highest quality
alternative to stock, used and inferior rebuilt axles,
Dynatrac has become the industry leader in performance
axles. Dynatrac's continuing commitment to quality
craftsmanship, engineering excellence, and unsurpassed
customer service, ensure you the best possible
experience when it comes time to repair or upgrade your
truck.
All of Dynatracs products are
manufactured in the U.S. and are based out of the
company's Huntington Beach headquarters and factory.
Dynatrac's R&D, manufacturing, sales, and service
processes are all under exacting standards consumers and
retailers demand of Dynatrac.
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