Thread: warn winch problems - help!

Hi all

I have been trying in vain to get my 13 year old Warn 9000 winch to work. To cut a long story short, I picked up the winch second hand about 2 years ago and had to buy a few pieces for it as it had a crack in the mount were the captive nuts are held. I have never used the winch since I picked it up.

Recently I fully stripped the winch and cleaned out all the rust and old hard grease from the gearbox and got it working smoothly. The motor on the other hand had some rust in it and I cleaned it out the best I could. After putting it all back together, the motor turns, but gets really hot after a short time.

The other problem is that the drum does not turn. I can hear the internal shaft turning but the drum is not turning. I have had the brake assembly out to clean it. I was able to remove the brake assembly without loosing tension in the internal spring. The pads look ok, but I am not sure in comparison to a new set.

I am really getting tired of it. A new motor is $470 and a brake assembly is $300.

Not sure where to go from here....

Cheers
Andrew

Well, there isn't much on an old Warn that can go bang, is there? Okay, the solenoids, maybe. Does the motor get unusual hot? It is common to get the motor heat up under load. As for the non-rotating drum, are you sure the clutch is engaged properly??? I had a similar problem once after assembly and had to wiggle the clutch lever really hard until I managed to get things going again. Also, make sure the brake is fitted correctly so it will engage. If there is still enough left on the pads I would re-use them, if you cannot get adequately priced replacement.
Cheers
BTW, there is an overhaul manual for your winch in the files section. Maybe you will find an answer there.