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Discussion Starter #1
Hey, I think this might be one of my first posts. Haven't been active on the Samurai in awhile, but this past fall I started ramping up the projects because I have a house and garage now.

Anyways, so my first priority is fixing up the driveline. In the process of rebuilding the front end, I replaced all bearing and seals, etc. and I also am installing a set of Warn hubs. During the final stage of the install, I put the hub base on and need to put the c-clip back on the end of the axle, but can't get enough slack. I've used a bolt and pulled. I've threaded a bolt through a socket where the socket was seated on the hub body and the bolt was pulling the axle out, but not nearly far enough. I forget the exact measurement, but I'm on the order of 1/10 to 1/4 inch short of being able to get the c-clip on and it's just NOT happening.

Has anyone else had this problem with the Warn hubs? My thinking was that perhaps they were manufactured for the Sierra/Jimny and something is just slightly different that prevents the axle from protruding enough for the c-clip.

In summary, can't pull the axle out far enough for the c-clip, but with the axle pushed all the way in, the splines still seem to have adequate mesh between the hub and axle, so is the clip really necessary?

So 1) has anyone else had or remedied this problem and 2) is it alright to just not use the c-clip?

Thanks All
 

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Without the clip you will lose the hub when you shear the hub bolts off.

The Warns have a tendancy to shear the bolts. The stock bolts are pretty small, but when you use conical washers like Suzuki does it makes the grip much tighter. Unfortunately, unless you champfer the holes in the Warn hub to match the angles of the conical washers they aren't going to fit right.

I run Warns on the rear on a full floater axle. I am running aftermarket bolts too. Haven't had any problems since going to the new bolts. This is what I am running:
Super Hub Bolts
 

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Discussion Starter #3
Yeah, I considered the hub bolt kit. Will end up going that route to prevent any shearing! I have enough problems with old, brittle, easily broken Suzuki hardware as it is.

So, do you run with or with c-clip and did you have the same problem of managing to get the axle out far enough for the clip? I thought about running a pipe cutter around the end of it to make a new c-clip groove. I just need someone to tell me if I'm not trying hard enough or just missing something. I even ordered the 50 mm socket to really crank the axle nuts down and still didn't get nearly the clearance I need for the clip.

A buddy just upgraded axles and they sent him 26 spline side gears for a Jimny/Sierra and they have a ridge that has to be ground down for use on a Samurai. Just wondered if this was a similar situation where a design update on the hub for the Jimny/Sierra prevents c-clip installation on the Samurai.

Out of additional curiosity, under what circumstance is a full-float rear a necessary upgrade? Sounds cool, but I haven't heard of too many people doing it.

Thanks for the input!
 

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When using the hubs up front, I have never had an issue with pulling the stub through far enough to use the C clip. I use them up front.
I don't have c-clip ridges on my rear axles.
I am running full floating axles because they were available for the axle housing I am running. I like them because they are easier to carry spares on the trail without carrying the whole outer assembly, so they are quicker to replace if you pop one. At least that was the thinking when I first installed the housing. To this date, I have not popped the rear axles (knock on wood).

This is the housing I run:
(the top axle replaced the bottom one)
 

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Discussion Starter #5
That's a clean looking setup. I'm nowhere near that extreme yet--still essentially stock and just trying to sure up the driveline before I start any suspension lift or get bigger tires. I have a buddy that's always pushing me to just do the bare minimum to squeeze 31s under it, but I'm more in the restoration mode before I go that route. I've seen the quick and dirty builds and they tend to break parts all the time.

Well so far I've just done the driver's side so when I put the passenger side back together, we'll see if I have the same problem with the hubs.

Thanks again.
 
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