Warn HS9500I rebuild

This site may earn a commission from merchant affiliate
links, including eBay, Amazon, Skimlinks, and others.

B

BROKEFINDER

Joined
Nov 28, 2016
Threads
1
Messages
27
Location
HOUSTON
I'm in the middle of refreshing my HS9500I. I wanted to look things over as this beast has been sitting around for a bit corroding away in the elements.

I ran into a snag as I could not find any info online who's done a rebuild or full disassembly.

I was a little forceful in knocking off the heat sink thinking it would pop off but it was attached to a the wire post via copper bar to the brush housing.

Does anyone know if the brush housing is press fit into the heat sink end? The copper bar attached to the post is a bit loose inside the housing from me trying to free the end off.

20250521_215738.jpg


20250521_215726.jpg


20250521_215951.jpg


20250521_220519.jpg


20250521_220757.webp
 
Last edited:
I soaked the edges of the brush cap and scraped with a pick to try and get some penetration with PB blaster over night.
Used a punch to rotate the brush cap so I could knock it out with the long bolts inserted pushing on the backside of the ring.

Now to try and straighten out everything I bent and get it all back together.

20250524_101228.webp


20250524_101516.webp


20250524_103028.webp


20250524_102015.webp


20250524_102018.webp
 
TLDR:
I need just a replacement brush holder bracket but it looks like they do not sell it individually. Motor has been superseded a couple of times over the last couple decades. Anyone got any leads to a replacement part? $200-300+ is insane to pay for a motor when I could spend a little more and get a new bigger winch with synthetic and Albright solenoid.


Well winch failed on me at the worst time. I was winching in and then it stopped. Solenoids were clicking in and out when engaged but no action from motor.

Bypassed the solenoid and nada. Figured it might have been rust but I didn't do any fording.

Took it apart and found the issue: a brush wire was pinched against the heatsink cap and brush holder.

Same thing again as before: the damn brush holder cap doodad was stuck inside the heatsink. It ended up breaking so I'm screwed with having to buy a brand new motor if I cannot find a new brush holder bracket.

1000050698.webp
 
gnob said:
do you have a starter/alternator 12volt shop around?
ive seen a few brush sets on ebay too.
Click to expand...
I'll have to see what shops are left. A lot of electronic repair shop closed over the past decade plus with the shift in consumer use to replacing vs repairing due to cost.

This design is decades old.... maybe I can adapt the newer design if the support bearing and distance is the same.
 
I do pro level Warn winch repairs, restorations and rebuilds at my full time shop "Vince's Winches". You'll find lowest priced parts are usually not even in stock or have hidden issues. Sometimes you get lucky and a shop wants to drop stock. Better off just spending the money (often only 10% more) and get not only real Warn parts but critical advice from an experienced dealer (like Montana Jacks). I dont sell parts so just dishing out some facts here.
 
You must log in or register to reply here.

Share this page

Back
Top Bottom