Warn HS9500I rebuild

BROKEFINDER · May 21, 2025

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.

BROKEFINDER · May 23, 2025

Warn HS9500i rebuild - end cap - https://www.pirate4x4.com/threads/warn-hs9500i-rebuild-end-cap.2706674/
Found the answer! Trusty old PBB

Now I hope it doesn't break when I try to separate it.

BROKEFINDER · May 24, 2025

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.