Randy88FJ62’s Warn 8274 rebuild thread (1 Viewer)

[Randy88FJ62]

Thread title updated to a rebuild thread: contrary to the title this winch will be going on the dirt road princess. My 2008 4Runner V8 sport edition (with 488,000 mi) only deserves the best. My FJ62 has a Warn M12000 which after delving into this rebuild I may be opening that sucker up for some R&R.

I am trying to remove the brake assy off a rusted 8274. I soaked the end in rust remover overnight and using a puller and pb blaster with hammer taps it won’t come off.

Any ideas on how to remove this would be appreciated.

 

[gnob]

A real puller is a good start.
You need to be pulling on the section closest to the case.

 

[Randy88FJ62]

A little jury rigging and the brake assembly came off.

 

[bj70_guy]

That's bringing a gun to a knife fight - nicely done!

 

[george_tlc]

So, I expect a new thread from you... How do I weld my rotor back together and how do I balance it.

j/k

good job!

cheers,
george.

 

[Randy88FJ62]

I’m struggling here. I got the brake assy off and now I’m watching a disassembly video. They pop the shaft out after lifting the plate. My shaft spins freely and moves past the plate a lot but won’t come out.

 

[Randy88FJ62]

What am I missing here?

 

[Randy88FJ62]

Perseverance.

 

[Randy88FJ62]

Tapping for zerk fittings on the end support.

 

[Randy88FJ62]

 

[gnob]

Clever idea with brake rotor.

Where's the rest of the zerk mod?

 

[Randy88FJ62]

Zerk mod drilled through nylon seal and end plate done successfully. Went easier than expected compared to the mess of disassembly.

 

[Randy88FJ62]

Aftermarket friction disks any cheaper?

WARN 98382 Winch Brake Friction Discs for M8274 Truck Winch, PAIR

FREE SHIPPING! WARN Winch Brake Friction Disc TWO Friction discs, for SINGLE disc, see 9734 For M8274 Truck Winch and previous versions of the 8274 Buy with confidence from Montana Jack's, we are your WARN Authorized Warranty and Service Center.We are a Factory Direct WARN Distributor and we...

www.montanajacks.com

 

[Randy88FJ62]

Same with this radial seal. Any good cross references for cheaper parts?

WARN 98393 Radial Oil Seal for M8274 Truck Winch

FREE SHIPPING over $35.00! WARN Radial Oil Seal For M8274 Truck Winch and previous versions of the 8274 REPLACES old number 7612 Buy with confidence from Montana Jack's, we are your WARN Authorized Warranty and Service Center.We are a Factory Direct WARN Distributor and we stand behind our WARN...

www.montanajacks.com

 

[Randy88FJ62]

Zerk mod done. Now do I buy stainless zerks or monel zerks for the extra corrosion resistance?

What zerk material would react least with the aluminum end housing? Hmm.

Housing painted in hi temp aluminum paint I had sitting around.

 

[Randy88FJ62]

I’ve seen brake clutches with pucks inside the holes. My brake assy came off with just the two rings of brake pad.
Is a standard brake rebuild kit ok to use here?

 

[DuckLN]

I’m lovin it! Keep em comin.

 

[Randy88FJ62]

Found out from reading amazon reviews of the brake kits that having the holes in the center area of the ratchet is ok using the newer brake pads. So I'll be ordering the brake rebuild kit.

My brake shaft (aka pinion shaft) is heavily corroded and pitted on the splines that interact with the main gear. I'm worried about its performance but questioning whether I want to pony up $140 for a new shaft. Hmm.

Question:
Does anyone know what the brake shaft o-ring replacement is in generic form if I ordered from McMaster?

 

[Randy88FJ62]

It’s quite hot today so I’ll take a break from cleaning the mechanicals and I took a look at the connector socket. It’s pretty rough.

Do people re pin these terminals themselves or give up and just buy a new socket?

The pinion shaft has some rough pitting on the splines. Do I run it or coin out $140 for a new one?

 

[1911]

It’s quite hot today so I’ll take a break from cleaning the mechanicals and I took a look at the connector socket. It’s pretty rough.

Do people re pin these terminals themselves or give up and just buy a new socket?

That's what I did; don't remember what it cost though.

The pinion shaft has some rough pitting on the splines. Do I run it or coin out $140 for a new one?

Wow, that is pretty rough. Even though that one will probably run, it would bother me knowing it's in there whenever I did a heavy pull, so yeah I guess I would replace it if it were mine.