Warn XD9000

Joined
Sep 11, 2012
Messages
482
Location
Vancouver, B.C.
Social distance means indoor project time! Replacing the broken drum support on the motor side. Got things apart easily enough, which is good. A washer popped out, and I can't tell which side of the support the washer goes on: motor side (inside the housing) or drum side? Also, is there any recommended sealant for the drum support to the motor? Anything else to do maintenance wise while it is apart? I will try to post pictures.
 
Joined
Sep 11, 2012
Messages
482
Location
Vancouver, B.C.
I might have picture of the area I think should be sealed. If I can find the file. Anybody know where to find a Warn service manual for this winch? I only got the user's manual off their site. Sorry about poor quality photo. Shows inside of motor. Sealant around outer rim of housing?
20200325_181312.jpg
 
Joined
Jun 25, 2012
Messages
300
Location
Delburne, Alberta
I've had good luck drilling and tapping the motor housing for a hose barb then running a vent hose somewhere high and dry. Seal the unit up as well as possible in tidy fashion with your goo of choice and you've got a little more resistance to the elements if desired.
 
Joined
Sep 11, 2012
Messages
482
Location
Vancouver, B.C.
What with staying at home almost full time, I have been over everything except the entire cable. It seemed fairly tricky to get the end cap off the motor to inspect brushes, so I did not fight with it too much. Cleaned and re=greased the gear end and pulled and inspected the brake. I might test the motor in the next few days, just by dragging the cable across the lawn. If it is not hammering down rain, I will put it in the bumper on the weekend. I know there is the odd burr on the cable, so I will likely switch to synthetic cable fairly soon. Any tips on the above would be appreciated.
 
Joined
Jun 25, 2012
Messages
300
Location
Delburne, Alberta
Lots of time for those 'later' projects these days indeed. I do feel synthetic rope is the future, still got steel on all my winches for now. Somewhere between being cheap and poor lol. Be sure to get a nice smooth fairlead at the same time you make the switch.

I pay alot more attention to how the cable goes on the drum then most people, I'll respool after every run if required, favourite way is to tension cable and use weight of truck sometimes with light park brake pressure, then spool in carefully checking cable frequently, will use pry bar to manipulate wraps nice and tight if required. I have a nice gentle slope and a farm yard to do this in, I do it from outside the truck. Best to have a friend at the wheel in case, but it can be done solo. A tiny bit of side load on a tensioned cable depending on where exactly on the drum the cable is at any particular moment will usually net a nice wrap regardless. Avoid crossing wraps if at all possible, this is what will damage your cable the most. Use your judgement on cable, a few pointy bits here and there isn't usually much of a problem, any deformation or flat spots sure as hell can be. If in doubt, fix.

Usually a good used cable or two on kijiji from people who have made the switch. Could be worth a look.

If you do go to synthetic, don't be afraid to chop out any bad bits of existing cable and keep it for an extension.

Lack of use disables more winches than anything else I've seen, the more you use it the happier itll be. I like to test mine the weekend before any upcoming adventures just in case.

Another favourite mod, I will weld a 1/2'' nut or possibly two to the inside corner of the winch drum, stick your cable through and put a cable clamp/crosby clip on the end so it cant pull through. After a onetime adventure inadvertently ripping the cable right off the drum in a sticky situation at night then proceeding to struggle to get the cable to bite again and take tension, this became a standard mod for me. Could probably stick syn. rope through and tie a knot on the end for same effect. It does make a bit of a lump on one end of the drum, but provided you don't leave any sharp spots, or weld spatter etc. it hasn't been a problem for me.

Happy tinkering.
 
Joined
Sep 11, 2012
Messages
482
Location
Vancouver, B.C.
@hiluxjeremy Thanks for the info. I thought Warn had a little thimble that held the cable in place? I haven't pulled all the cable off to check. Just charging a battery now to test. I was looking at Amsteel synthetic rope for the future. Mostly I want to switch to save weight. Safety a bit too because I break everything and I don't want to be around when a steel cable breaks.
 
Joined
Jun 25, 2012
Messages
300
Location
Delburne, Alberta
Right on, yep, you're not wrong.

My Warns did indeed have a basic crimped on eyelet at the end of the cable secured to the drum by a rather undersized fastener, one of which the eyelet was already torn in half, another the fastener was broken off flush with the drum. Neither one would I choose to rely on when things get extra dodgy. I've also seen drums that only had a hole to jam the end of cable into but I don't recall if it was on a Warn, coulda been a cheapo many moons ago.

I don't doubt there were variations over the years, some versions probably better then others. It is true they were never intended to see any load beyond getting enough wraps on the drum for the cable to get a good grip. But, sh#t happens, especially in the woods, at night, and just a little too far from that anchor point. Only my opinion though, I'm sure results will vary.
 
Top Bottom