How To Reassemble Aisin Locking Hubs

[IH8Wood]

Disclaimer: I really have no idea what I'm doing.
I found the FSM sort of confusing on this, so I have a different approach that seems more straightforward.

This assumes your locking hubs are dissembled. You should have a bunch of parts that look like this:

 

[IH8Wood]

Install o-ring, spring, and steel ball into the control handle.
Then install the control handle into the hub cover....

 

[IH8Wood]

Install snap ring...

 

[IH8Wood]

Wind the tension spring into the clutch...

 

[cruiser88]

This needs to be in the tech links if its not already.

 

[IH8Wood]

Notice that the compression spring is not symetrical. The narrow end of the srping goes towards the follower...

 

[IH8Wood]

Put the follower against the narrow end of the spring and push the follower into the cover. There are two tabs in the follower that fit into two slots in the cover. Twist the cover and follower in opposite directions so the follower screws into the cover...

 

[IH8Wood]

Reassemble the free wheel hub ring and spacer to the inner hub. Install the snap ring...

 

[IH8Wood]

You should now have four parts (from upper left to bottom right):
the inner hub, the cover, the hub body, and the clutch.

 

[IH8Wood]

Note that at this point I differ from the FSM. Install the inner hub into the hub body and then install the snap ring...

 

[IH8Wood]

Install the clutch into the hub body. Make sure that the tip of the spring is lined up with one of the small teeth...

 

[IH8Wood]

Now back to the cover. First set the control handle in the free position.
Next rotate the follower so two teeth line up with the slot in the cover.
If you see a bunny rabbit you've got it right...

 

[IH8Wood]

Place the cover into the hub body. Make sure that the spring end goes between the follower teeth...

 

[IH8Wood]

While pushing the cover down, rotate it slightly back and forth until it drops completely in. Make sure that control handle rotates between free and locked and then replace the cover mounting bolts.

 

[FinHJ60]

Now that the clutch and the follower aren't hooked together, what makes the hub unlock?

I say you need to hook the tension spring over the follower, as in FSM, so that the follower can pull the clutch out.

 

[ad20k]

Excellent job! I nominate for the FAQ.