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Thread: Winch Service (warn)

  1. 13th September 2008, 07:58 PM #1
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    Winch Service (warn)

    Well this started out as a service and turned in to a head ache

    First job is remove the wire cable or synthetic rope from your winch to save on weight ,Then remove the winch from the bullbar ,
    If you are not able to do this dont bother with the rest

    If you are unsure to where your power cables go mark them with a paint pen for the control box and the motor
    Next with the winch removed its time to remove the motor
    after cracking the allen head bolts and if you dont have allen sockets you can use a screw driver to undo the bolts

    Remove the motor and be suprised at the inside of the drum where the brake is , mine was not that bad as what had been suggested hey mat(t)

    to remove the brake you need long nose pliers ,and squeeze the 2 tabs together and at the same time pull the brake with shaft out of the drum , The brake shoes will fall out once the shaft is removed but dont stress you will see how it all goes back together

    See the motor in the botom of the pic it has the coupler on the end of the shaft that operates the brake

    Brake shoes and shaft



    I cleaned the brake shoes up on a wire wheel on a bench grinder a wire brush will do the same

    To clean the inside of the brake drum i used a hone , when using the hone do not lubricate it use it dry , a wire brush will do the same with a bit of work

    Mmm the motor need i say anymore




    I will edit the post and add extra pics as the questions come in , so keep coming back to recheck it
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  2. 13th September 2008, 08:11 PM #2
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    Winch service

    Well after the shock of the motor and the $$$$
    The gearbox was next
    Mmm water has been in there

    the gearbox is simple as to dismantle and to assemble


    I cleaned all the grease off all the gears and cleaned the gears and re greased them with waterproof wheel bearing grease
    Mmm 6hp motor

    In thr pic is the cap off my 2.5hp motor which i thought was a 4.6hp motor
    Now i sand blastered all external parts then etch primed them and applied a top coat of paint
    Oh and when you assemble the gearbox and motor use a very small amount of silastic to help water proof

    The only tricky part of this was putting the brake back together
    hope you enjoy
    Oh and a before pic
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  3. 13th September 2008, 08:14 PM #3
    mcrover Guest
    Hey Chris, did you get around to checking the windings for shorts or open circuits? As with a clean up on the wire wheel, that armature looks as though it wouldn't come up too bad in the photo, may look worse in real life though.

    I know you went up to a bigger motor but that may do as a good spare or EBay job

    Magnets are all there so they should be ok with a clean out, change the brushes and should be right.

    Looks great now, maybe too good to hide behind the bull bar lol
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  4. 13th September 2008, 08:18 PM #4
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    Quote Originally Posted by mcrover View Post
    Hey Chris, did you get around to checking the windings for shorts or open circuits? As with a clean up on the wire wheel, that armature looks as though it wouldn't come up too bad in the photo, may look worse in real life though.

    I know you went up to a bigger motor but that may do as a good spare or EBay job

    Magnets are all there so they should be ok with a clean out, change the brushes and should be right.
    Have a look at the windings they are starting to melt

    It might be a bit hard to see
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  5. 13th September 2008, 08:19 PM #5
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    Good job Rangieman, thanks for this!
    Cheers
    Slunnie


    ~ Discovery II Td5 ~ Discovery 3dr V8 ~ Series IIa 6cyl ute ~ Series II V8 ute ~
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  6. 13th September 2008, 08:21 PM #6
    mcrover Guest
    Ok, thats what that thought it was rust

    Oh well, clean it up, Dulux reco and EBay is your freind, no warrenty
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  7. 13th September 2008, 08:22 PM #7
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    Quote Originally Posted by Slunnie View Post
    Good job Rangieman, thanks for this!
    Like i said the only pain in but part is the brake but not realy
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  8. 13th September 2008, 08:33 PM #8
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    Quote Originally Posted by rangieman View Post
    Like i said the only pain in but part is the brake but not realy
    I was wondering about that, but I didn't see any particular reference to it so thought it must just be a PITA to get back together or into the drum. Was there anything in there to beware of or is it just a PITA. I liked the hone job in the drum to clean it out though. I assume this was done dry or did you clean the oil out later?
    Cheers
    Slunnie


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  9. 13th September 2008, 08:46 PM #9
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    Quote Originally Posted by Slunnie View Post
    Good job Rangieman,
    ^^^^

    Ahh, its good to see the low mount grunge I spoke of
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  10. 13th September 2008, 08:49 PM #10
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    Is s missing a spline or is it supposed to be like that? Whats the shaft go to?

    Cheers
    Slunnie


    ~ Discovery II Td5 ~ Discovery 3dr V8 ~ Series IIa 6cyl ute ~ Series II V8 ute ~
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