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Dana 60 locking hubs coming unlocked

bp71k5

3/4 ton status
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Mar 31, 2006
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The drivers side hub keeps moving off of the "free" setting while driving. I've read there is some kind of set-screw solution I can do but does anyone else have this problem? These are the warn premium style.
 
35 spline outers? I've read about 35 spline outers rubbing in the inside of the dial causing it to turn. If this is the problem swapping the stock inner wheel bearing race for a D60 carrier bearing race will push the hub assy out approx 1/8" and fix the problem.
 
35 spline outers? I've read about 35 spline outers rubbing in the inside of the dial causing it to turn. If this is the problem swapping the stock inner wheel bearing race for a D60 carrier bearing race will push the hub assy out approx 1/8" and fix the problem.

yes, 35 spline outers.

ugh, I hate messing with bearings. But that sounds like my problem. I wonder if I could clearance the hub instead?
 
I have heard about folks grinding material off the end of the stub shaft but I don't know how much.
 
I've got 35 spline outers with Warn premium hubs and i don't have any issues. I have however heard of people having this issue and IIRC you can just grind a small portion from the end of the stub axle to cure this problem.
 
What brand are your outers? I've read that only spicer outers rub the dial. I have Yukons with zero problems rubbing the dial.
 
I've got spicer outers so maybe there's something to that. So far, it's just the drivers side. I've got some tape to keep it locked until I can deal with it.
 
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