Warn 9.5Ti Rebuild (2 Viewers)

Mudder · Apr 26, 2015

I finally got around to tearing into the second winch for my truck. A warn 9.5Ti. This winch has been inside most of its life but I wanted to get some fresh grease in it. I started by removing the clutch side, after that I undid the bolt holding the clutch mechanism and cleaned the clutch level really well tor remove all the old grease than I removed the gear and cleaned the clutch housing and the gear for the clutch. Make sure you know how it came out as it'll go in both ways and only work one! I think pulled off all the top pieces so I had better access and took lots of pictures. I also made sure to label where all the bolts came from and if there were any differences I noted those. I than removed the snap ring holding the planetary gears on the clutch side. Then I slid off the first gear cleaned it up really good, than removed the second gear.

Then I tried to undo the solenoids on to have one of the rings break on me

$C:\Users\CarMal\AppData\Local\Temp\msohtmlclip1\01\clip_image001.gif$

so now I have to figure out how to remove that nut and then crimp on a new gear terminal. After that I gave up on remove the small wires and worked around it and just removed the bigger wires so I could remove the motor. After I got the drum off I removed the brake shaft which took some force, watch out as the brake pads will come out with you wanting them to! I thank cleaned up the drum and brake shaft and reinstalled it, pushing it most of the way in before putting on the brake pads. Than I found out that a bold had gotten broke off, now I just have to figure out how to remove it. After all that I proceeded to clean out the rest of the grease from the drum supports and removed the other side. Now I'm just waiting for warn part #64642 from Summit.

While doing this rebuild I read through this thread, http://www.greatlakes4x4.com/showthread.php?t=69556. I highly recommend reading it as he talks about some stuff, mainly the grease that I won't.