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How-to

1992 Ford Bronco Dana 44 Warn Lockout Swap

1992 Ford Bronco · Swap · Easy

Documented by SuperMotors from Jeremy Millrood’s photos

The Mile Marker locking hubs on a solid axle Dana 44 are replaced with Warn lockouts, one side at a time. Jeremy Millrood switched after one Mile Marker lockout exploded during off roading and notes the process should be the same on any Dana 44.

  1. Step 1

    Lay out the new lockouts before starting. Jeremy Millrood reports that the Warn lockouts come with all the hardware needed for the swap.

    Replacing the milemarker lockouts with Warns on my solid axle Dana44, but this process should be exactly the same to any Dana 44. A little… (1992 Ford Bronco) Here are the shiny new Warns. They come with all the hardware you need to swap. (1992 Ford Bronco)

  2. Step 2

    Back out the six retaining screws in the lockout cover with a hex head bit and lift the cover off.

    Old milemarker hub, they use a hex head bit on the retaining screws. (1992 Ford Bronco) 6 total and the lockout cover should come right off. (1992 Ford Bronco) A gloved hand is shown adjusting a chrome hubcap on a vehicle's wheel. Several lug nuts are scattered on the wheel rim. (1992 Ford Bronco)

  3. Step 3

    Fish the retaining ring out of its recessed area with a pick. Pushing the lockout body in as far as it will go makes the ring easier to reach.

    next step is to fish out the retaining ring. this holds the lockout body in place inside the hud. It sits down in a recessed area. With a p… (1992 Ford Bronco) A gloved hand uses a tool to manipulate a splined hub assembly on a vehicle's wheel. (1992 Ford Bronco) and there's the ring. (1992 Ford Bronco)

  4. Step 4

    Thread a couple of the bolts into the lockout body and use them to pull it free of the hub. It should slide right out.

    now use a couple of your bolts to pull the lockout body free from the hub..it should slide right out. (1992 Ford Bronco) A person wearing blue nitrile gloves is shown working on the hub assembly of a vehicle. The hub appears to be a manual locking hub with vis… (1992 Ford Bronco)

  5. Step 5

    Do not add grease to the new lockouts, since the Warn units come pre-greased and extra grease can affect how they work. With the old lockout out of the way, this is also a good time to check the bearings.

    with the old lockout removed the new one is ready to go in..the Warns come pre-greased, you don't want to add anything else to them as it c… (1992 Ford Bronco)

  6. Step 6

    Slide the new lockout body into place and seat it fully, then refit the retaining ring. On TTB axles, add the snap ring supplied with the lockouts to the end of the axle shaft; Jeremy Millrood notes it is not needed on the solid axle.

    new lockout body slides right into place. on the TTB axles you will need to add the snap ring (comes with lockouts) at the end of the axle… (1992 Ford Bronco) new lockout body fully seated and don't forget the retaining ring. (1992 Ford Bronco)

  7. Step 7

    Install the cover bolts, then turn the dial on the lockout to confirm the front axle engages and disengages, and repeat the swap on the other side. The photos end here.

    ready to button it up..once you put the bolts in for the cover, check the dial on the lockout to make sure you can engage and then disengag… (1992 Ford Bronco)

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