Has anyone ever posted an installation of maunal locking hubs? It seems to be an easy upgrade, but I just wanted to read some tips from someone that has actually done it.

Also it seems that Warn #29091 will work on a 2004 Xterra, but that year is not listed in the hub specs. Any advice?

Yeah, 29091 works for all 00-04 Xterras.

There's a write-up at nissanoffroad.net in the how-to section, but it needs revision. After removing the outer shell, the next step is to remove the snap ring, and then you can remove the entire internals of the hub in one piece. Removing the internals in 2 pieces is NOT advised as they are damn near impossible to put back together.

Brent

Thanks OffroadX! That is exactly what I was looking for! It's a good tutorial and I appreciate the personal tip. Thanks again!

I've found that the Warn service kit for the Warn hubs(#29061) comes with a gasket that is not included in the #29091 Hubs. I like to use this gasket from #29061 because I feel the rubber o-ring that comes with your Warn hubs is not sufficent enough to seal against water intrusion. That o-ring is the only thing between water and your bearings. #29061 comes with a gasket that goes between the Xterra hub and the Warn hub. It's a real tight fit and that o-ring can get easily damaged during installation. I've been careful to tighten the nuts down so to slowly and evenly seat the Warn hub onto the Xterra hub and have still pinched and tore the o-ring. I kept getting water in my bearings/hubs and found this to be the culprit. Even have had my Warn hubs warrantied twice due to this. Now I'm on my third set and no issues since servicing the bearings the last 2 years. Even if you don't damage the o-ring, that hub gets hotter than the Warn hub therefore expanding the Xterra hub sealing surface at the o-ring on the Warn hub, causing the o-ring seal to be comprimised. Just my theory and expierence. All I know since I started using that service gasket #29061 when I do my annual bearing service, I haven't had any more water issues. Now, I do use a product called "Indian Head Gacsket Compund." It's a brown tar like goop that I apply to both sides of the service gasket prior to installation. It's perfect for this use. I use it on my thermostat housings as well.