Got around to installing the Aisin hubs this past weekend. Very easy job to do...the hardest and most time consuming part was removing and reinstalling the snap rings.
For just general information Aisin manual hub FHM-002 and FHM-003 will fit Gen 1 and Gen 2/2.5 Monteros,Pajero,Shogun. FHM-002 has the metal dial and FHM-003 has the plastic dial
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grimgs, on Flickr
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grimgs, on Flickr
Before you do anything make sure the manual hubs are in the "Free" position before you install them.
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grimgs, on Flickr
Hub face bolts are 14mm.
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grimgs, on Flickr
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grimgs, on Flickr
Mitsubishi calls this a "hub cap" which in essence is. This isn't a twisted on threaded cap..you have to pry it off.
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grimgs, on Flickr
In order to remove the auto hub base you will need to remove the snap ring on the end of the cv shaft. A good set of snap ring priers will do the job...even the set I bought from Harbor Freight worked fine. The snap rings don't have the "holes" on the ends so it takes some skill and patience to remove them and reinstalling them.
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grimgs, on Flickr
Once you get the snap ring off you should be able to pull off the hub face and expose the hub assembly. Take the opportunity to clean off the old grease and inspect the hub and bearings. Here pictured is after I cleaned off most of the hold grease. Prior to installing the manual hub base apply some wheel bearing grease.
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grimgs, on Flickr
After you apply new wheel bearing grease go ahead and install the hub base. Since there is no gasket..apply some RTV sealant on the mating surface to help keep a seal to prevent water / debris intrusion. You can use a little bit a Loctite or not before you thread in the 14mm bolts back. Thread them all to snug and then torque them down like wheel lug nuts in a star pattern. FSM suggest 38-42 ft lbs but I torqued mine at 40 ft lbs.
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grimgs, on Flickr
Once the hub base is installed go ahead and apply some wheel bearing grease inside. Make sure the hub face gasket is aligned and then thread in the bolts. The Aisin hub face bolts are 10mm and do NOT require a lot of ft lbs to torque them down. I torqued them down till I got resistance and half turn.
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grimgs, on Flickr
After you install them just turn the knob to make sure it turns and test drive.