Thread: My D90 warn xd9000i service

Finally get my WARN xd9000i winch serviced and now in running condition.
Last usage was during a rescue mission, pulled not even 5 feet of distance and the motor just didn\'t want to run anymore. The load was reasonable and not much stress put on the winch itself, I think it must been over worked for the past few trips.

Ok.. first to confirm either it is the motor or the relays which is giving the problem, open up the relays box and checked. The condition is very good and dry.



reconfirmed with multimeter, both wiring and relays in working condition. [bad news for me]



Next was to dismentle the whole unit of winch to find out what is the actual problem.
step 1 : dismentle the relay box (6pcs screws), take out the whole unit.

step 2 : pull out the motor side, where the motor shaft will come loose from the coupling (alu type).

From there you can access to the brake assembly parts


step 3 : unscrew the heat sink from motor body



step 4 : unscrew the gear box part and slightly knock it out with a mallet.


step 5 and the rest are very straight forward, see and take out

And see what I found after dismentle the motor part.

A burned rotor, rusted shaft

A burned coil - smell like carco

burned carbon brush - can be salvaged


Its confirmed I got myself a burned xd9000i motor

When came to the gear box part, the suprise is not less than the motor part.





See what I found inside my winch... extra value added material


Put all the parts into a pan full of diesel and let it soften the old grease for 2 days.

After few round of washed and rinsed, the things look like this.



For the burned motor solution. Buy a new one and just plug and play but it cost a boom in my pocket.. Warn 4.6hp new and made in Brazil by BOSCH. Below photo shows the size of motor, slightly longer but it came without heat sink.



Everythings put back to their original place and its time to fit it back to my jelopy. But before that, there is a minor improvement to be done. The winch table top was so well designed that the gap within the winch and plastic grill is less than 20mm, which will damage the grill if the wire rope coiled to one side.



A simple solution was made by using the left over 1.5mm checked plate to cover up the real side of the winch.

Reinforced by tighten both left and right with the relays box's screw.


The blue color cable is pre-fitted for in cabin winch controller by using salvaged hoist controller button. Will be posted later..

The End?

Great work i'm shore many people will find this thread handy!!!

TIM.