Has anyone sucessfully managed to repair the autohubs on the early Explorer (91-94)? Is there a repair kit anywhere? Ford wants something like $900 for new ones. I put Warn manuals on my '91 and the autohubs just failed on my wife's '92. I'm completely happy with the Warn hubs but my wife has a tendency to get all flustered when she has to get out of the car and turn them. The first time she did it she forgot to release the parking brake and drove about 50 miles with it on. Worst brakes shoes I've ever seen. The last time she drove it she released the parking brake but forgot to turn the hubs. It was driven about 5 miles in 2WD with the hubs locked but with no apparent damage. I guess my point is that sure, the Warn manuals are the prefered option here, but if there is a simple way to get the autohubs working again my life would be simpler and have fewer repairs ;) At least she always remembers to back up after switching back to 2WD with the autohubs.
What kinds of bad things will (or should) happen if you drive in 2WD with the hubs locked (Warn)? I've done it on purpose a couple of times when it was raining and was only going a couple of hundred feet on pavement and then back to the mud. Nothing seemed to be binding or make any wierd noises etc.
For that matter has anyone ever had to replace autohubs on an Explorer (early model) that they bought new and always remembered to back up to unlock the hubs after going back into 2WD and never abused? I'm guessing that most of the hub repairs I've read about here were on Explorers that were bought used, keeping in mind that they came from an era when it was a status symbol to have 4WD especially if you had absolutely no need for it. No doubt some of those previous owners either NEVER pushed the 4X4 button or used it when they shouldn't have.