Front hub lock washers

[PaulS]

I disassembled two sets of steering knuckles this weekend--one pair was on the D25 that is probably original to my CJ3A, and the other was on a D27 that may be from a CJ5 (69-70?).  One thing (of a few) that surprised me was the condition of the lock washers (the big ones that go behind the nuts holding the hub on). Of the eight of them (two per hub), I think more than half had noticeable damage, and two or three (on different axles) were really trashed.  Is this normal?  Why/how do those things get damaged?

-Paul

[PaulS]

Here's the worst offender:

[Rus Curtis]

It looks like that washer has had some material cut off at some point.� I would guess that either it's been abused beyond service or one of the previous owners thought that by modifying the washer to create "tabs" would make locking and unlocking easier.�

There are two washers with each hub.� I believe the thicker washer goes against the bearing and the second washer is placed between the two nuts.� This washer is thinner and based on the directions, should be bent down over the outside nut to lock it in place, after adjusting the inner nut.   vernco.com suggests starting a bend after scribing the nuts position - making the final bend easier when inside the hub.

Hopefully, those were placed in the �discard� pile.

[1955CJ-5]

That is amazing....someone spent a lot of time and effort ruining that washer...

[PaulS]

It's the fact that I had trashed washers on two different axles, from two different POs that really surprised me.  Made me wonder if this is something common.

I don't actually have a discard pile yet.  But I will...  The king pin bearings from the D25 probably belong on it, too. And all the seals/gaskets.  For now, everything is going into baggies labelled with the axle (25/27) and L/R, so I'll know where it came from (more or less).

-Paul

[PaulS]

I should try to get a picture of all eight washers together...

-Paul

[PaulS]

All four of the outer washers have damage--gouges or dents/bends.  But three of the inner ones are okay.

[Rus Curtis]

Paul,
Bending on the outer washer is normal as that is the method of locking the outer lock nut.  Some bend this washer both ways (inwards and outwards) in an attempt to lock both nuts but IMHO, this is unnecessary as the inner nut is held in place by the outer nut which is locked.  This of course is assuming proper seating of the bearings.

The wear on the inner washer on "25R" is NOT normal.  Careful inspection of that hub is a good idea.  Hopefully the bearings were the only casualty.  Look for wear on the spindle and inner surface of the hub.

[PaulS]

Isn't it supposed to be just the tab that gets bent, though?

[Rus Curtis]

Paul,
Tab?  Are we referring to the �modified� a.k.a. molested washer in "25R"?  Since that needs to go into your discard pile, I�d recommend not using it again. 

An unmolested outer (large) washer is as it appears on the �25L� image.  That other little tab, on both washers (inner/outer) that appears on the inner surface, goes into the groove or channel on the spindle to keep the washers from spinning � tab faces out so as not to ground out or press against inner washer-and preventing proper tightness on the nut.  Therefore, when you bend over a section of the outer edge of the thinner (outer) washer down over the outer nut, you lock it in place since the washer can�t spin.

A flat washer is hard to bend outwards with the available gap inside the hub.  A technique I like to use is to install and set the inner nut.  Install the outer washer and nut.  Scribe (or mark with permanent marker) the outer washer where I want to bend it.  Remove outer nut and washer.  Using pliers or a vise, start a slight bend just above the scribe so that when reinstalled, grabbing that portion with a screwdriver edge is easier to complete the bend down onto the outer nut.  Only one bend is required to lock the nut.

Is that more confusing?

[PaulS]

No, that makes sense.  All the outer washers are bent, even if it's not clear in the image.  I think you've explained why quite clearly.

I figured there had to be a reason...

Now the modifications to 25R (i.e, the right side of the D25 axle), that's a different question altogether!  It looks like someone wanted tabs on the outside of the outer washer.  The wear on the inner one is interesting as well.  I don't recall seeing any damage on the spindle or bearings...  But this was the only hub of the four where the oil seal popped right out when I pulled the hub off.