I found the threads on the Aisen manual hubs and that enabled me to remove and replace my bearings and seals, but upon reinstalling the hubs I have a problem nobody has addressed. I have the whole assembly together and installed all the way to the cap, but the cap will not mount up to the housing no matter what I do. I figure I am overlooking something, being unfamiliar with how these things operate. The link from one of the threads helped, but I am still not getting the cap to mount flush. It seems to be stopped by something about 1/4 inch or less from the housing and will not go any farther. What do I need to adjust or realign and how do I do it to get this ligned up properly?

any chance you could post some pictures?

I'm having a hard time visualizing what you're describing.

check schematic I emailed you....good luck

ASSEMBLY

Apply grease to both faces of spacer and install.
Apply grease to inside face of ring and install.
Install snap ring, then apply grease to splined portion of inner assembly body and install.
Install snap ring, hub lock ring, detent ball and spring,
Apply grease to outer circumference of knob and inner circumference of cover.
Align detent ball with groove of cover and install knob.
Install snap ring with smooth surface toward knob.
Install clutch assembly retaining spring.
Install follower to clutch. Ensure follower nail comes close to the bent portion of retaining spring by aligning follower stopper nail to outer teeth of clutch, then hook retaining spring onto upper portion of hanger nails of follower.
Install compression spring with smaller diameter toward follower.
Install clutch assembly as follows:
Align follower nail to handle groove then assemble clutch with knob by pushing and turning clutch counterclockwise to knob.
Using tools J-36828 and J-8092 or equivalent, install two outer races then two outer bearings.
Coat hub with grease, then apply Besco L-2 or equivalent to inner and outer bearing.
Turn hub so chamfer is aligned to the tapped hole on outer side, then using tool J-36827 or equivalent, install hub nut.
Using a spring scale, adjust bearing preload to 3.03 lbs.
Install lock washer with larger diameter of the tapered bore to the outer side of vehicle. If bolt holes in the lock plate are not aligned with the corresponding holes in the nut, reverse the lock plate. If bolt holes are still out of alignment, turn nut enough to obtain alignment. Ensure screw is fastened tightly so head is lower than surface of washer.
Apply Loctite 515 or equivalent, to body assembly and install.
Install snap ring and shims, then adjust clearance between free wheeling hub body and snap ring. Clearance should be 0.01 inch. Available adjusting shim are .008, .011, .020 and .039.
Align and install cover assembly torquing bolts to 8.7 ft. lbs.

Perfect! That schematic is exactly what I needed. evidently I have a few parts out of order. I can already see that. I'll go after it again tonight and see what happens. With the directions you gave and the detailed schematic I should be able to figure it out. Thank you so much.

Also, keep an eye on the outer teeth on the "gear" and how they line up with the hub body. The hub body will have some skinny channels and some wider channels. THe "gear" has all skinny teeth; but there is another piece of the hub that spans across some of the teeth. The teeth that have this piece 'connecting' them must go into the wider channels. I tried my best to make that make sense! <img src="/forums/images/graemlins/lol.gif" alt="" />

Thanks. That was exactly what I needed. I put them both together this last weekend without any problems at all. The diagrams were especially helpful. It drives better than ever. Also for anyone who has vibration problems in the front end, bad bearings will cause that also. All the vibrations I had are also gone now.