Hub dust cap installation

Previous owner punctured a hole in both the front left and right dust covers. I’m talking about the circular cap that is a press fit right over the axle nut.
I got replacements online and for the life of me can’t get them in. They appear to be the right size so I’m thinking we’re talking about being a thousandth of an inch off, if at all.

I tried lightly tapping it with a brass mallet on the edges to get it in, but to no avail. I didn’t have a metal file available but thought if I used one around the edge it might help. Thoughts on this? Anyone else have other installation tips?

 

Yes. I had this problem when I changed my front wheel bearings. The new hubs ID must have been a tad smaller than stock, so same problem.
I took a pair of channel locks and started slightly bending in the lip on the cover. Just go a little and work your way around the dust cap. Eventually, it will fit.

 

Interesting. I'm a bit skeptical to try this as it seems to me (I could be completely wrong) that this would cause a bit of "waviness" along the outer edge instead of it being a smooth curve. I'd be worried this wouldn't make a seal. I'll certainly keep this idea in the back of my head if all else fails, it would be 1000% better than having gaping holes in the covers like I've got now!

 

This cover just protects the axle nut, everything else behind it is sealed. A small deformation in that cap isn't going to cause any issues unless you're doing a lot of underwater driving.

 

Mine were definitely not perfect along the edge anymore after a shop did some work on my truck. I found it when I had to pull the dust covers for swapping my bearings. There was an obvious dent/bend in one spot along the edge of each dust cap. Maybe they couldn't even fit the original back in without bending it a bit. It looked fine under it, so I'm not too worried. I just put it back on.

 

Did you get oem? If not maybe that's why it doesn't fit perfect. I replaced one and it was very tight but eventually did get it to line up and go on. I bought one from the dealership it was a little pricey

 

I took side cutters and snipped the edge. This allowed the edge to bend just enough to get it to flex and start.
If you are worried about it. RTV the spot you made the cut.

I wasn’t worried about it. I still had to take rubber mallet and tap mine in.

And I’d say 50% or more of the one that have ever been removed are mangled anyway.

Pro tip: A wood chisel works great to get the cap started off. It gets in to the groove nicely.

 

It really just helps you get it started. It's still a nice interference fit when it seats. I put a little grease around mine before I tapped it in. I figured it would help fill a few thousandths of gap if there were any. I also greased the splines of the axle shaft before I reinstalled everything so it would minimize seizing for the next bearing replacement.

 

A dab of grease on both interfaces goes a long way (and easier to remove the cap the next time you need to).

 

These things are stupid tight; I'm unfortunately old enough to have worked on lots of 1970s cars that used this style of cap. The Tacoma caps are the tightest I've ever experienced. I used a ~2mm thick paint scraper on mine to get them off- and I have all sorts of scrapers, chisels.... They actually make a special plier to remove these that I purchased after this but haven't needed to use.

 

Just us an extended socket that fits into the cap and pound it in with a hammer. I was not able to tap it in with just a hammer either.

 

so you're concerned about some deflection on a cover but have holes punched in the current ones? roll the edge just slightly. I usually throw just a small amount of anti-seize on them and tap them home with a rubber mallet usually if I work around them in a circle you can pop them right in. you want a pretty tight fit so they don't get thrown out. you will be fine lots of older cars I've owned, or trailers with the classic dust caps been installed that way.

 

I just went through this dance last night. I found a trick.

The main issue is it never wants to go in straight; so one side invariably goes down to the hub flange and the other pops up. Then you're playing wack-a-mole and just chasing the high point around in circles (or hacking up the cap). I tried some grease, I tried using a file to put a little chamfer on; always the same game. I eventually got one pounded in.

Then I went to the other side, pulled my head out of my ass and realized this would get a lot easier if the axis of the two things I am trying to press together were even just a little closer in line. Being off axis creates this eccentricity of sorts that requires the cap to deform a lot before it will go in to place. I found something in the garage about 3/16" or so thick that I could rest on the wheel studs and would act as a spacer in between the hub flange and the lip on the cap (my piece in particular was a claw style seal puller, but I think even a chunk of wood or something would do the trick). Two hits with a rubber mallet and it was on its way in. Turned it in to a very satisfying task.