yall should just sell those and get a t-max. hehehe
Warn 9.5XP motor water damage
- Thread starter hzavarce
- Start date
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Bumpin' this BTT.
My HS9500 has been non-functional for almost 2 years now, I tried to use it to pull someone out of a ditch in an ice storm, and when I tried to use the motor to spool out the cable, I heard a nasty SNAP and that was it, no more worky.
So today I finally took it off the bumper and tore it apart. I gotta say that even though it's 6 years old, I'm pretty disappointed with the lack of weatherproofing on this thing. BOTH ends have significant water damage, and all of the bolts and cap screws were a challenge to get out. I'm really not sure I'm gonna be able to salvage it. This model is no longer available, so I'd have to replace it with a 9.5XP, best price I'm seeing is around $1250, a 50% increase over what I paid for this HS9500.
I read this thread, and looked carefully at the instructions (I still have them), there is NOTHING in them about opening up a drain in the motor for any type of mounting. I can see the drain in the casting, it looks to me like it was originally clogged with grease. Mine is a foot-down setup. I'm pretty sure this motor is junk, it's very corroded inside. A new one is almost $400 from Warn.
The part that snapped is a small planetary gear unit on the motor side, it's called the "Stage 1 carrier assembly". But Warn doesn't sell just that piece, you have to buy the entire drum support, another $225. WTF???
I guess I'll call Warn on Monday, but I'm pretty sure they're gonna tell me I'm SOL.
My HS9500 has been non-functional for almost 2 years now, I tried to use it to pull someone out of a ditch in an ice storm, and when I tried to use the motor to spool out the cable, I heard a nasty SNAP and that was it, no more worky.
So today I finally took it off the bumper and tore it apart. I gotta say that even though it's 6 years old, I'm pretty disappointed with the lack of weatherproofing on this thing. BOTH ends have significant water damage, and all of the bolts and cap screws were a challenge to get out. I'm really not sure I'm gonna be able to salvage it. This model is no longer available, so I'd have to replace it with a 9.5XP, best price I'm seeing is around $1250, a 50% increase over what I paid for this HS9500.
I read this thread, and looked carefully at the instructions (I still have them), there is NOTHING in them about opening up a drain in the motor for any type of mounting. I can see the drain in the casting, it looks to me like it was originally clogged with grease. Mine is a foot-down setup. I'm pretty sure this motor is junk, it's very corroded inside. A new one is almost $400 from Warn.
The part that snapped is a small planetary gear unit on the motor side, it's called the "Stage 1 carrier assembly". But Warn doesn't sell just that piece, you have to buy the entire drum support, another $225. WTF???
I guess I'll call Warn on Monday, but I'm pretty sure they're gonna tell me I'm SOL.
- Thread starter
- #25
KLF, I would also send an email with more facts, like a copy of your manual.
If it is not clear, or says nothing at all they feel more responsible
Mine was out of warranty and they still took care of it.
Good luck ! let us know hoe it goes
If it is not clear, or says nothing at all they feel more responsible
Mine was out of warranty and they still took care of it.
Good luck ! let us know hoe it goes
I called Warn Customer Service, they didn't seem too sympathitic, although he did say that their winches are covered for lifetime for defects in manufacturing. IMO, this is a manufacturing defect. As far as I know, it's not a maintenance item to have to tear a winch completely apart every year and make sure it's not full of water. This winch has NEVER been under water (I don't roll that way), and I don't think I've used it more than 6-8 times at the most. I tried and tried, but the motor is unrepairable. The bearing at the outer end of the armature is totally rusted to the armature, but it is all crunchy and nasty. I can't get the plastic brushholder out of the end housing either, so now there's no way to get it back together.
He said they can't diagnose a warranty coverage of over the phone (understandable), so I have to ship it to an authorized repair shop and have them make the call. I guess I'll have to take the chance. Now all I have to do is find a strong enough box...
BTW, he said that whole "open the drain hole" thing only applies to the 9.5XP in a foot-forward mounting.
He said they can't diagnose a warranty coverage of over the phone (understandable), so I have to ship it to an authorized repair shop and have them make the call. I guess I'll have to take the chance. Now all I have to do is find a strong enough box...
BTW, he said that whole "open the drain hole" thing only applies to the 9.5XP in a foot-forward mounting.
this is another great example of why i do not understand everyone's die-hard loyalty to Warn. Every time a winch thread gets going everyone says spend the extra money and buy a warn since it is bullet proof and will never fail. I bought a t-max 12,500 and saved over $500, have used it numerous times and still have no water issues.
I just don't understand....
I just don't understand....
lowenbrau
SILVER Star
I totally agree. I bought a 9000 when they first came out in the early 90s and had my first surprise not long afterward. Mine was mounted feet down and still looked much worse than the one originally posted. I cleaned it up semi annually thereafter and eventually had the motor rebuilt and finally gave up on the winch altogether within five years. If you regularly use your rig in in mud you should probably choose something other than a planetary Warn. An 8274 is still very good value. Mud leaking into the drum of that winch doesn't end up in the motor.
I'm surprised at how good the factory 80 series winch seems to be once you replace the main shaft with the upgraded version. I haven't had an opportunity to really abuse mine yet though.
Mark W
Yep, I really don't really care that much I guess.
PTO,PTO,PTO 
Or maybe a hydro
Mark...
Or maybe a hydro
Mark...
bjowett
Supporting Vendor
This is why I am buying a Warn Deep Fording Series 12.... unfortunately they use a different mounting pattern, but that can be remedied.
Update:
I pulled the winch line off, packed up the winch, shipped it off to Hoaks 4WD Center in PA. I also included copies of all the original docs & receipt, and a 2-page letter explaining how it failed and I discovered the water damage.
Just got off the phone with the tech, Warn took care of it, even the return shipping. New motor, gearbox, planataries, line brake, gaskets, etc. Total rebuild, on their dime. He said it's basically a brand new winch. So, my faith is restored, huge relief.
The tech Eric was really friendly, explained that it's not a bad idea to at least pop the gearbox section off occasionally and check the grease. He also said it's not good for them to sit unused. Even if you just unspool and respool it occasionally, it helps. I guess that makes sense.
I pulled the winch line off, packed up the winch, shipped it off to Hoaks 4WD Center in PA. I also included copies of all the original docs & receipt, and a 2-page letter explaining how it failed and I discovered the water damage.
Just got off the phone with the tech, Warn took care of it, even the return shipping. New motor, gearbox, planataries, line brake, gaskets, etc. Total rebuild, on their dime. He said it's basically a brand new winch. So, my faith is restored, huge relief.
The tech Eric was really friendly, explained that it's not a bad idea to at least pop the gearbox section off occasionally and check the grease. He also said it's not good for them to sit unused. Even if you just unspool and respool it occasionally, it helps. I guess that makes sense.
- Thread starter
- #33
NICE !!!! this is the kind of news one wants on a Friday PM !!! cheers ! 
Warn quality
I have two Warn XD9000I winches. I bought one new in 1993 and it has seen alot of use over the years. The other was made 1992 and I bought it used from a friend to put on my 40. It had seen alot of hard use, looked like crap, but mechanically it seemed fine. I re-built and painted it just for my peace of mind. I e-mailed Warn when I was re-building the winch to find out what the best overall grease was to put in the winch. Warn sent me the re-build gaskets and decals for the winch free of charge. Internally the winch was in great shape and now with some new grease, gaskets, and synthetic rope it is better than new. I also have a Warn 3000 on my atv. I have never had an issue with any of my winchs. If I ever do I feel certain that Warn will take care of it for me. When you buy a Warn you are not just buying the winch. You are buying a quality product that is backed fully by its maker. BLIND DEVOTION TO WARN, no just years of good experience and faith in a great company.
I have two Warn XD9000I winches. I bought one new in 1993 and it has seen alot of use over the years. The other was made 1992 and I bought it used from a friend to put on my 40. It had seen alot of hard use, looked like crap, but mechanically it seemed fine. I re-built and painted it just for my peace of mind. I e-mailed Warn when I was re-building the winch to find out what the best overall grease was to put in the winch. Warn sent me the re-build gaskets and decals for the winch free of charge. Internally the winch was in great shape and now with some new grease, gaskets, and synthetic rope it is better than new. I also have a Warn 3000 on my atv. I have never had an issue with any of my winchs. If I ever do I feel certain that Warn will take care of it for me. When you buy a Warn you are not just buying the winch. You are buying a quality product that is backed fully by its maker. BLIND DEVOTION TO WARN, no just years of good experience and faith in a great company.
