Help needed on rebuilding a Warn M10000

[Bryan E.]

I picked up a basket case, Warn M10,000 winch tonight. It needs major re-building. Had water get into it. Bad thing is that it was taken apart by original owner so I'm going to try to clean it up, repaint and rebuild it to look like new.

Motor is in really bad shape but I've read about them being cleaned up and guys have gotten them to work again.

Needing a cover for the electrical parts with the plug for the remote cable, remote control and the rope which I hope to get synthetic but might go back with wire rope for now.

Wished that I could have gotten a nicer one, all pretty and working but being on a tight budget lets you learn all about these items from the inside out so when I get it working again, I'll sure know all about rebuilding it.

Located in Dallas area.

No camera to take pictures right now but will try to get some posted soon. Now to search for the parts needed.

Will eventually want to go with a synthetic rope, 3/8 by 125' or might be looking for a take off new cable that somebody took off to go straight to synthetic. Tight budget and all. Who's got the best deal on the synthetic rope and what do you recommend?

Any tips, recommends on parts, etc. will be appreciated in the rebuild.

Thanks,

 

[Bryan E.]

Parts needed so far are solenoid cover with the plug end for the remote, remote control, winch cable (3/8" x 125') and possibly a motor rebuild or replacement and one of the side to side bars that separates the two sides.

I'm cleaning out all the old grease and dirt of all the parts and rust here and there.

What would you recommend to clean the motor insides? Not sure if this part is going to be salvageable.

What kind of grease or oil is used for lubrication of the gears?

If you've had one of these winches, or a M12,000 all the way apart, I sure could use a little help with assembly tips.

Have a long way to go before it's ready for cable but would appreciate recommendations and sources.

Thanks,

 

[LittleRock80]

eBay Store - CustomSplice: Mainlines, Extensions, 1 2 AmSteel Winch Rope

FWIW....
I found this store on eBay. Very reasonably priced AmSteel blue. Never bought anything from him though.

RockStomper.com has fairly resonable prices as well. I have bought from them before and had a positive experience. Very helpful staff as well.

That M10000 is a classic! Not sure when WARN quit making that model.

Good luck,
Jwp

 

[Bryan E.]

Hello JWP.

Thanks so much for your reply.

I'm leaning towards getting nice, synthetic rope instead of wire rope. Will have some time to think about it and shop for the rope as I am working on the rest of this thing.

I'm cleaning it and have every piece all on a bench. Motor was rough but I think it can be salvaged. I'm going to make sure the motor works, then repaint everything, get it all back together and maybe even mount it and wire it up, then will be ready to install new rope.

Thanks for your help.

I'll check them out.

 

[Bryan E.]

Took motor all apart and got the caked mud and bad crusted rust out. One broken brush inside the motor will need replace. Bearing is also shot. Working first to try to salvage this motor.

Warn wants about $75 just for the electrical cover with the plug for the remote. This seems expensive to me for a plastic cover. Might have to make this cover but will need a plug. Can I get a plug to match the remote from an auto parts store, three pin style?

Also do you see any reason that I couldn't use aluminum diamond plate to make a switch cover out of? I could also use sheep steel, which would actually be easier anyway but I've got some of both.

What grease will I want to use inside the gear box?

I know that these winches are not water proof from factory but is there a way to seal it off and lessen the flow of water inside?

How many side to side bars did these come with? I'm only finding three with mine but seems like it should four.


Sure would like to take every part to get powder coated but probably will just paint it with heavy duty paint. Looks a lot better with the layers of mud, muck, rust, old grease being removed.

If anybody happens to have an original instruction manual, I would love to get a copy of it. Trying to find all kinds of info on it, like wiring diagram, maintenance, and complete parts list but even Warn doesn't show much of this stuff on their site. Their parts diagram isn't even complete and no where can I find lubing instructions or anything on wiring it up to the vehicle.

Thanks again for your help.

 

[Jeeper]

When I rebuilt my 8274 a while back, I took the motor to a starter/alternator shop. They professionally cleaned it and checked it for internal shorts in the windings. Then I bought new brushes from Warn (they were a Bosch part). Done.

On the remote plug, I purchased the plastic solenoid cover from Warn -- $25ish as I recall without the plug. I used a 4-pin trailer plug that just hung out of the solenoid box, and I cut off the remote plug and wired in the mating connector. This worked fine, but I really didn't like how much force it takes to push those trailer plugs together and take them apart. Maybe buy the weatherpak connectors that are used for underhood sensors...

Or you could hard-wire the controls to a dash mounted switch and forget about the remote connection altogether.

Warn has incredible customer service. Call 'em up and ask them anything about the repair of that winch, and they'll route you to one of the 2 guys in the back who know everything.

Maybe some info on my old site here that helps:
4wdJEEP.com :: Warn Winch 8274 Rebuild

Good luck

 

[GulfShoresFJ60]

Here is a guy that has made a solenoid cover out of aluminum plate:

https://forum.ih8mud.com/merchandise-storefront/307491-8274-solenoid-pack-covers-made-aluminum.html

 

[toywilly]

I just had mine totally ripped apart and did basically the same thing your doing. I have no pictures however but if you have any specific questions fire away. There are only three tie bars as the spot where the fourth would go needs to be open so the cable can pass. Also I emailed wanr and they got me a pdf of the wiring diagram which I cant seem to find right but warn was very prmt to reposnd to my email.

 

[Bryan E.]

Thanks for all the new replys and help tips.

Jeepers...Thanks for the link. Different winch but a lot of the same, rust and crud inside my motor. Good ideas about the starter rebuilders to re-do the motor, and a new brush kit.

Gulfshores...thanks for the link to the aluminum cover. Those look really nice.

Toywilly....Thanks for the offer. I will probably be emailing you.

To the tips about contacting Warn. I've been doing this. Scott's helped me out a lot but since I got this winch in a box all taken apart, I'm still just trying to make sure that I even have all the parts. I need to email them a picture and see if it's all here. Sometimes a bargain isn't as much of a bargain when you completely re-build things but then again, at least I will know it's nice when I'm done and also know how to rebuild it in the future if needed.

Thanks again for the help.

 

[Bryan E.]

Found a motor on Ebay

I found a direct replacement motor on Ebay. Looks exactly like my motor but this is rated like the new ones that Warn sells, 4.5 hp. Mine was rated at 2.5 hp but I think that they rate them differently now than they used to and I don't believe that it is almost double the power. At least it would be all new parts completely. Might be the ticket. What do you think? The splined shaft on mine is really chewed up and the bearings are rusted in place, and almost gone.

Here's the Ebay motor.
NEW WARN WINCH MOTOR XD9000 XD9000I MX8000 M8000 MX6085 : eBay Motors (item 400099825041 end time Feb-25-10 18:03:27 PST)

Warn lists the motor part as No. 26629 which is one that this listing says that this motor replaces.

$89 and free shipping. Oh yes, I'm getting excited now.

 

[toywilly]

found the wiring diagram warn sent me. Mine is set up in the three wire configuration but I was told some ahd the five wire config. it all depends on what controller you use.

 

[Bryan E.]

Need a brake pad

Thanks Toywilly for the wiring diagram. I think it was a three pin factory set up and I wonder what the five pin set up would be needed for? I'm sure there is a reason some do this set up.

For now, I'll just be ecstatic to even get the thing running again back to stock configuration. Got a long ways to go on this project.

Found out there are three brake pad parts in the brake mechanism, but I only had two in the box of parts. They are not available from Warn as pads only but you must buy the entire brake system which is over $300 which is crazy. If I can't find an original, I'll be forced to machine one myself. Should be easy enough if I can find some type of material that will work which might be difficult to find.

I'm excited to get a winch but realizing that I might have been a lot better off looking for one that was all together and working and in nicer shape. Well, I have hopes of seeing this project through to the end but it's a challenge.

Thanks for all the help guys.

 

[Alister]

good luck with that.

 

[Bryan E.]

Still don't have it put back together but Scott from the Warn Tech dept. really came through for me. Found the one brake pad that I was missing, and got a new set of brushes for the motor, gaskets, solenoid cover, etc. and I still need to buy a remote and some kind of winch rope. Hoping to go ahead and get synthetic rope. Needing wiring to hook it all up. I'm taking the time to clean it up inside and out while it's all apart and re-painting everything as I go.

Still have high hopes for this winch

 

[AJAEbj42]

I used a simple SPDT switch (with center off) mounted to a piece of plywood for my remote. I know, please don't laugh, but hey, it was a $5 remote and it's hooked up to my winch via a 5 pin trailer connector (only wired 3 of the 5 pins as mine is as 3-wire winch from 1986).

Works just fine and it's a real conversation piece on the trail, let me tell you.