The 1986 Suzuki Samurai WARN Premium Manual Hub Kit is a high-quality 4WD conversion system designed specifically for the 1986 Suzuki Samurai. This premium hub kit replaces automatic locking hubs with durable manual locking hubs, providing improved reliability, better fuel economy, and reduced front drivetrain wear. The kit includes all necessary components for complete installation and is engineered for off-road performance and longevity. Below are key sections covering features, installation, operation, maintenance, and troubleshooting.
Key components: Premium manual locking hubs, installation hardware, gaskets, and detailed instructions.
| Feature | Description |
|---|---|
| Manual Locking Hubs | Durable construction with positive engagement mechanism |
| Premium Materials | Hardened steel construction with corrosion-resistant coating |
| Easy Operation | Simple 2-position switch (LOCK/FREE) |
| Complete Kit | Includes all necessary hardware for installation |
| Improved Fuel Economy | Reduces front drivetrain drag in 2WD mode |
| Enhanced Reliability | Eliminates automatic hub failure points |
| Off-Road Performance | Designed for rugged terrain and heavy use |
| Direct Replacement | Specifically designed for 1986 Suzuki Samurai |
| Maintenance Friendly | Easy to service and rebuild if needed |
| WARN Quality | Manufactured to WARN's premium standards |
Complete installation requires basic mechanical tools and approximately 2-3 hours.
WARNING! Always use jack stands when lifting vehicle. Ensure all fasteners are properly torqued.
After installation, verify proper operation before driving.
CAUTION! Do not engage 4WD on dry pavement. Always test in safe, controlled environment.
Manual hubs feature simple two-position operation for engaging and disengaging 4WD.
FREE Position: Hubs disengaged - front wheels freewheel for 2WD operation with improved fuel economy and reduced wear.
LOCK Position: Hubs engaged - front wheels locked to axle for 4WD operation. Must be in LOCK position before shifting transfer case to 4WD.
Operating Procedure: Stop vehicle, turn hub dials to desired position, shift transfer case accordingly. Always engage hubs before shifting to 4WD.
Regular maintenance ensures optimal performance and longevity.
Tip: Always clean hubs thoroughly before any maintenance to prevent contamination.
| Symptom | Possible Cause | Corrective Action |
|---|---|---|
| Hub won't engage | Dirt/debris in mechanism | Clean hub assembly and lubricate dial mechanism |
| Difficulty turning dial | Corrosion or lack of lubrication | Apply penetrating oil and work dial back and forth |
| 4WD not engaging | Hub not fully locked | Ensure dial is completely in LOCK position |
| Grinding noise | Worn internal components | Inspect and replace worn parts using rebuild kit |
| Hub feels loose | Loose mounting bolts | Torque mounting bolts to 25-30 ft-lbs |
Reset: Disassemble and clean if persistent engagement issues occur.
Service: Contact WARN technical support for complex issues.
WARN Premium Manual Hub Kit includes limited lifetime warranty covering defects in materials and workmanship. Warranty does not cover damage from improper installation, abuse, or normal wear. Proof of purchase required for warranty claims.
Always engage and disengage hubs with vehicle stopped. Never force hub dial - if resistance is felt, clean and lubricate mechanism. Always use jack stands when working under vehicle.
CAUTION! Do not attempt to engage 4WD while moving. Ensure hubs are properly engaged before using 4WD.
WARN Industries provides comprehensive technical support for all products. For installation assistance, troubleshooting, or warranty claims, contact WARN customer service at 1-800-543-9276 or visit www.warn.com. Have product serial number and vehicle information ready when contacting support.