I recently embarked on an overhaul of my Warn 9.5xp winch. There were quite a few lessons learned (some painful), so I thought I would share.
Why did I overhaul my winch?
Over the last 3 years, the winch has been submerged numerous times (once even operated submerged). I bent up the MetalTech front bumper on my 80 and it had to come off for some welding.
The winch worked fine, I'm just a little anal on PM.
I'll be referencing the parts list often, you can find it here:
http://www.warn.com/truck/winches/95xp_winch.shtml
This guy did a nice write-up with pics, but I found it lacking on several details which I'll touch upon:
http://www.wanderingtrail.com/Repairs_Rebuilds/warn_winch/warnwinch.html
This is not a complete step-by-step guide.
1) Brake Disassembly:
The brake assembly inside of the drum is "wound". If you remove it from the drum without securing it, it will unwind. A mistake I made. I searched the internet for quite a long time and nobody has a procedure to re-wind these brakes. Luckily, Warn is a great company and re-wound my brake for free. However, this cost me ~2 weeks of down time. When I got it back from Warn, it was in a cardboard sleeve to keep it secure.
If I were to do it over, I would partially remove the brake from the drum, tighten a hose clamp around the brake, then completely remove.
2) Parts List
For the planetary gears, Warn calls for Aeroshell 17. This was replace by Aeroshell 33ms. 17 and shouldn't be mixed with 33ms, so it needs to be cleaned out. Aeroshell is available at aviation stores (BM/online) and isn't cheap ~$15. The internet is full of advice about what else could work, but I stuck to what Warn recommended. Why go cheap on a +$1k winch.
In addition to greasing up the gears, the bushings and seals (#20, 19, 14, & 13) on the Drum Supports (#6 & 21), need greased. On teardown, I noticed that this grease was a translucent green color. (as apposed to the dark grey color of the grease on the gears). I contacted Warn and they informed me that they use "[FONT="]albida grease" in this location.[/FONT] I'm not sure [FONT="]whether that is Shell Albida[/FONT] SLC 220 or 460. Mobile 1 Synthetic was very comparable to 220, so I went with that.
4. Motor Seals
There are two paper seals used on the electric motor. Item #22 is shown on the PL but is not available for purchase. The other seal is not shown on the PL or available to purchase. It is located under the finned motor cap. I found this fact annoying. Warn was nice enough to send me item #22 free and suggested I use a high temp FIPG for under the cap.
5. Motor Seal Drain
Note that there are 2 drain slots on Item 21 Drum Support. The one facing down in your application should be left open and the other filled with high temperature sealant.
Why did I overhaul my winch?
Over the last 3 years, the winch has been submerged numerous times (once even operated submerged). I bent up the MetalTech front bumper on my 80 and it had to come off for some welding.
The winch worked fine, I'm just a little anal on PM.
I'll be referencing the parts list often, you can find it here:
http://www.warn.com/truck/winches/95xp_winch.shtml
This guy did a nice write-up with pics, but I found it lacking on several details which I'll touch upon:
http://www.wanderingtrail.com/Repairs_Rebuilds/warn_winch/warnwinch.html
This is not a complete step-by-step guide.
1) Brake Disassembly:
The brake assembly inside of the drum is "wound". If you remove it from the drum without securing it, it will unwind. A mistake I made. I searched the internet for quite a long time and nobody has a procedure to re-wind these brakes. Luckily, Warn is a great company and re-wound my brake for free. However, this cost me ~2 weeks of down time. When I got it back from Warn, it was in a cardboard sleeve to keep it secure.
If I were to do it over, I would partially remove the brake from the drum, tighten a hose clamp around the brake, then completely remove.
2) Parts List
- Warn PN 68614 Seal Kit (qty 1)
- Warn PN 13826 Housing Gasket (qty 2)
- Toyota FPIG
- Aeroshell 33ms Grease (needed about 1/2 tube)
- Mobile 1 Sythetic Grease (needed about 1/4 tube)
For the planetary gears, Warn calls for Aeroshell 17. This was replace by Aeroshell 33ms. 17 and shouldn't be mixed with 33ms, so it needs to be cleaned out. Aeroshell is available at aviation stores (BM/online) and isn't cheap ~$15. The internet is full of advice about what else could work, but I stuck to what Warn recommended. Why go cheap on a +$1k winch.
In addition to greasing up the gears, the bushings and seals (#20, 19, 14, & 13) on the Drum Supports (#6 & 21), need greased. On teardown, I noticed that this grease was a translucent green color. (as apposed to the dark grey color of the grease on the gears). I contacted Warn and they informed me that they use "[FONT="]albida grease" in this location.[/FONT] I'm not sure [FONT="]whether that is Shell Albida[/FONT] SLC 220 or 460. Mobile 1 Synthetic was very comparable to 220, so I went with that.
4. Motor Seals
There are two paper seals used on the electric motor. Item #22 is shown on the PL but is not available for purchase. The other seal is not shown on the PL or available to purchase. It is located under the finned motor cap. I found this fact annoying. Warn was nice enough to send me item #22 free and suggested I use a high temp FIPG for under the cap.
5. Motor Seal Drain
Note that there are 2 drain slots on Item 21 Drum Support. The one facing down in your application should be left open and the other filled with high temperature sealant.
