M12000 rebuild

[florida95fzj]

Good morning everyone,

I've soaked my gear box parts in a cleaner to remove the grease but am wondering if it's necessary to remove all of the surface rust. I expect it would take a soaking in something like Thermocure although I don't know how safe that would be for the gear box. I tried some rust removing gel but that didn't work much.

 

[gnob]

hit the steel with a wire wheel and move on.

 

[florida95fzj]

So I got the gear box assembled and I can't get the new motor to fit correctly. I got a Warn 77505, which should fit a M12000. I assume I have something out of alignment but it seems like the shaft has bottomed out.

I never removed the brake so I assume it's in the right position in the drum. I've got the motor coupler as far down as I can.

Any ideas?

Taking a break before I reach for the drawer with the mallet.

 

[gnob]

the armature fell out of the brushes?
pull off the other end to look

 

[florida95fzj]

the armature fell out of the brushes?
pull off the other end to look

Other end looks good. Turned out to be I was wrong about the brake. It wasn't fully seated where it needed to be on the shaft. I thought it didn't move but I must have moved it.

 

[florida95fzj]

Making progress. Bad news is I can't free spool the drum. It's locked and doesn't move. The lever rotates 360 degrees and moves the cam.

Looking at some other rebuild videos, it appears the freespool ring completely comes out of the gear housing. Should the entire ring spin freely inside of the gear housing?

 

[gnob]

yes it comes out. the free spool handle allows it to spin or not.

 

[gnob]

go through my vid

 

[florida95fzj]

Great video. I had been looking for this all weekend and didn't remember where it came from.

I also have one of these levers that rotates 360 degrees. No spring that I noticed. No snap ring in the gear box. Warn's drawings only show that entire gear box assembly as once piece. No details on the parts inside. Warn also says there's no service manual for my m12000.

I'll have to dig in again and see if I can get the freespool ring out. I know it was spinning. It wasn't completely seized.

 

[gnob]

mine is an older model. im sure warn made changes. there really are no manuals, just the exploded views that we work from.
thanks for watching.

 

[florida95fzj]

That video should be in some kind of sticky thread.

Now let's hope I don't have the 50+ ball bearings in there.