Just finished my Winch Rebuild

[Romer]

My FJ40 came with an XD9000i Warn Winch. When I tried to hook it up I got sparks and smoke. The PO said it worked for him.

Learned a lot, followed this video to validate my solenoids were good



I then bench tested my motor and validated it was bad



I used this instructions as a guide and it was very helpful

http://www.wanderingtrail.com/Repairs_Rebuilds/warn_winch/warnwinch.html
The parts breakout was very helpful as well

Took me a while to find those resources so thought I would share

Waiting a few days to let the paint dry before I add the cable

 

[LittleRock80]

Nicely done, Sir. Looks great. I loved my XD9000i, great winch.

 

[Romer]

All done and on the vehicle

 

[onlyonedr]

Looks great. So how does that work exactly? Your winch cradle detaches from the bumper? I have never seen that done before.

 

[Romer]

Its a multi-mount. It has a hitch end and plugs into a normal trailer receiver. The PO had a custom front bumper made with a receiver made.

I can see advantages to being able to use it on multiple vehicle or the rear. I personally would have preferred a hard mount, but I do like the look of the custom bumper.

The cradle wiggles as it isn't a snug fit so I may look into making holding brackets or developing a hard mount. BUT that's low on my priority list

 

[ontopofm]

How many hours did it take to do a rebuild? I bought a used one and thinking of doing a rebuild myself.

 

[Romer]

Maybe 10. Not sure did it over a couple weeks.

Also, I put a shim in the receiver and that took care of 90% of the wiggle so I am good with the setup now

 

[Romer]

BTW here is the multi-mount kit or you can buy the whole system. If I was buying a new winch I would take a good look at the XEON winches

The nice thing about the setup is it uses Anderson Connectors to hook it up to the battery. I should probably get an extension so it would work on the back receiver