Warn winch rebuild

[Bird]

Well today was assembly day for the spare winch... I have 2, and both are XD9000's.
new bearings and gaskets, grease/moreys mixed throughout (that moreys stuff is insanely tacky and like honey !!) fully expoxyed as per the thread from patrol forum...


line up the motor parts


Nice and cleaned up properly... no 1/2 measures.



Assembly of the motor went well


Looks a touch better and will not corrode this time

[Bird]

The Gearbox.

Mix up the concoction..



this Shit is the bomb... its so tacky you can do a couple of cobwebs without trying.. 



Sitting the bits in place before coating them with the mix...



So covering it as much as possible and running it into the gears and down the sides and lots!



More gears and more goop


At this point sat the rod in place and used a cordless to test the gears were seated properly (no photos hands were way too coated but they will never rust...) and to run some of the goop around through the gearbox.. all went well.

Reassembly of the brake section with cleaned up drum and pads etc.



Then putting it all together ready to bolt the braces on.



Then wired up on the bench and test run in both directions and free spool tested - all ready to rumble!!!!!!!!! 

Much thanks to Stunt Hands again for his assistance.. Now to do the second winch  and sell one.

[D4D]

You should do that for a living

[GeoffA]

You should do that for a living

Yep. Looks better than new....

You got final $$ yet?

[Bird]

Yep. Looks better than new....

You got final $$ yet?

... on the assembly after cleaning

Moreys was the most expensive part.. $20something - but I only used about 50-100ml out of the bottle
Grease $10 -  only used about a handful..
2 new warn gaskets $5
2 new warn plastic drum bushes $15
Tin of epoxy paint $20
Brake Cleaner I already had several tins of it at home
Bearings $10 for 2 from local bearing place - SKF bearings.

... and use of Stunt hands machinery, emery paper, lathes, benches,  rubber hammers, rags, brake cleaner as solvol did nothing to clean my hands from that Moreys Shit... Even the brake cleaner struggled..

[GeoffA]

So, under $100 incl bearings, brushes etc??

[Bird]

So, under $100 incl bearings, brushes etc??

I'd forgot the bearings, so added them... brushes cleaned up perfectly.
And surprisingly easy to do.

[Bird]

You should do that for a living

too dirty for me... still digging Shit out of fingernails from the weekend pulling it apart!

[Bad Scott]

Looks awesome. Good work Bruce

[GeoffA]

So, under $100 incl bearings, brushes etc??

I'd forgot the bearings, so added them... brushes cleaned up perfectly.
And surprisingly easy to do.

Do it yourself.....

[Jason B]

I'm in the market for a low mount, as I sold the hi mount 

[Black Diamond]

Good work Bruce

[Bird]

Good work Bruce

thanks dude.. 1 down 1 to go..

[achjimmy]

Great stuff well done.  Did you go the offset tierods too?

[Bird]

Great stuff well done.  Did you go the offset tierods too?

not with this one, but going to with the second one. I've not nested with this one, I'm pretty careful feeding it on, it doesn't take much

[feisty]

Thanks for sharing - nice job well done!

[GeoffA]

It's too nice. You won't want to get it dirty now......

[Bird]

It's too nice. You won't want to get it dirty now......

fairlead - what sort did you use for plasma? Photos? offset or normal?

[GGV8Cruza]

Looks great Bird, did you do anything to keep the water out of the internals?

GG

[Brett B]

Nice job mate   

[GeoffA]

fairlead - what sort did you use for plasma? Photos? offset or normal?

Normal roller fairlead, but with nylon rollers.

[Bird]

Normal roller fairlead, but with nylon rollers.

ahhhh ok...

Any advantage of one over other you think?

[GGV8Cruza]

fairlead - what sort did you use for plasma? Photos? offset or normal?

Running plasma and a hawse on mine, just need to watch when winching in a large angle off to the side. The weight difference from a normal roller fairlead and and aluminium hawse is crazy

GG

[Bird]

Running plasma and a hawse on mine, just need to watch when winching in a large angle off to the side. The weight difference from a normal roller fairlead and and aluminium hawse is crazy

GG

metal rollers? Or swapped to the plastic?

[loanrangie]

metal rollers? Or swapped to the plastic?

Hawse = alloy , no rollers.