Warn M12000 motor horrorshow

[DannyboyUpstate]

Hey Fellas! First post here. I'm a Land Rover guy, but have been lurking here for awhile. Great information here on the site.

So I have a Warn M12000 on a truck I recently purchased. The PO told me that one of the solenoids in the control pack was failed. I tested them. One was failed as described.

I ordered a new WARN 83668 contactor control pack to replace the whole old style solenoid control pack. As I was removing the old cables from the winch motor, of course one of the terminals snapped off. I pulled the winch from the truck. Then I removed the motor to try and replace the terminal. Of course the motor got filled with water at some point, is seized and full of corrosion.

Here are the questions:

Is it worth rebuilding?

Or just buy another one from WARN for like $220? I'm afraid that the new WARN motor may not be as heavy duty as the original motor.

I am not interested in an aftermarket motor at all.


Thanks for the input fellas!!

 

[DirtaddictLC80]

That does look nasty. Let's see some pics of the motor and the housing separated.

Easy test...clean it all up, reassemble and bench test the motor to see if it works. Maybe the cleaning will un-seize it. Even if it works, you can still decide (for piece of mind) to replace with a new one.

Don't forget to check out that bearing in the housing cover as well.

 

[DannyboyUpstate]

That does look nasty. Let's see some pics of the motor and the housing separated.

Easy test...clean it all up, reassemble and bench test the motor to see if it works. Maybe the cleaning will un-seize it. Even if it works, you can still decide (for piece of mind) to replace with a new one.

Don't forget to check out that bearing in the housing cover as well.

I'll take it apart today. This machine has sat for a long time before I got my hands on it. I never even had a chance to energize it, so my hopes are that it hasn't taken a beating with all the gunk inside the motor.

 

[KLF]

I had that happen to my HS9500 several years ago. Water got into the gearbox at the planetary and froze, then I went to use it to pull a car out of a ditch in a snowstorm, as soon as I hit the switch there was a BANG and that was it. By the time Spring got here and I pulled it apart, water got into the motor and it was junk, looked pretty much just like that.

I complained to Warn, as I had hardly used it, and it had never been dunked. I had to put it back together and ship it to a repair place down in PA. Warn warrantied the motor, but I had to pay for the parts in the gearbox and the shipping, which I decided was a decent compromise. The place that did the repair told me that I really should plan to take the thing apart occasionally and check the lube, etc. even if I don't use it. I wish the owner's manual had mentioned that.

 

[alia176]

Dannyboy,

I'm more interested in seeing that chain hoist setup of yours. Let's see some pics of the garage!!!

Oh yeah, tech content: take that motor to a starter/alternator rebuild shop and see what they can do. They can do some amazing things with rotors/stators/windings these days. Also, price out the new 6hp motor for the XP series winch and see if it's a PnP on your winch. I think your 12,000 motor is the same size as my 10,000 motor, which is 4hp I *think*.

 

[jonheld]

The first generation M12K was a 2.5HP motor. The second gen was 4HP. I have a 2.5 on mine and it pulls well.


Shop around for a replacement motor. We had 2 guys in our local club that needed replacements. Some of the Warn dealers may be able to help.


It's difficult to tell from the pictures, but I don't think there's too much left to service. You'll need new bearings, new brushes, new commutator and possibly new windings on the field coils. The only thing that would be salvageable is the magnets and I've seen them break free from the housing.

 

[titanpat57]

an I love NY sticker and an ARB roofrack on a Rover....

this can't possibly end well....



Welcome to Mud..that winch needs some serious help!

 

[DannyboyUpstate]

an I love NY sticker and an ARB roofrack on a Rover....

this can't possibly end well....



Welcome to Mud..that winch needs some serious help!

HAHA, I'm not clear on the stigma of the roofrack on my truck?








We're looking good with some new parts now. Con-Rel, the local auto electric shop said there's no hope for the old one. They offered me an aftermarket replacement for $169. Saw similar motors online for $89. I am leery of a cheap motor.

Ordered a new motor from Warn via Amazon. $212 shipped. That was reasonable. I didn't upgrade to the XP motor because I spoke to Warn tech support and they said they haven't really tested it. I was worried that

 

[DannyboyUpstate]

the newer motor might strip out some part of the planetary or the motor coupling or something.

 

[cicak]

HAHA, I'm not clear on the stigma of the roofrack on my truck?

We're looking good with some new parts now. Con-Rel, the local auto electric shop said there's no hope for the old one. They offered me an aftermarket replacement for $169. Saw similar motors online for $89. I am leery of a cheap motor.

Ordered a new motor from Warn via Amazon. $212 shipped. That was reasonable. I didn't upgrade to the XP motor because I spoke to Warn tech support and they said they haven't really tested it. I was worried that

Lol we have 8274 upgraded 2 winches to 6hp fine. Its called field testing. WARN need to get out more lol. Will put a 6hp in the m12000 also in my volvo soon.

 

[DannyboyUpstate]

OK, so the saga is over. Here is the old motor after I took it apart. The starter shop couldn't do anything with it unless it was irreplaceable.

So I went to install the new motor, I inspected the gear train first. Everything looked good there. I bought a new outboard bearing from a local industrial bearing supply. Put the motor and the winch all back together, mounted it on the bumper, mounted it on the truck and, click NOTHING. The drum was seized to the fxxxing housing. The ONE piece I didn't take a part or mess with.

Entire thing back apart.

Ordered a new brake assembly, all new plastic bushings and thrust washers, and driveshaft. All and all, I have $550 into the whole ordeal. Now EVERYTHING is MINT on the thing. Operation is flawless and hopefully good for at least another few years.

Thanks for all the advice.

 

[alia176]

Very nice!!

 

[wagonteeth]

For future reference, I had an M8000 that needed a new motor and went with one from these guys. It was a great unit with higher power.

http://www.wms1.com/