Warn XD9000i rebuild

Joined
Jan 22, 2019
Messages
48
Location
Flowery Branch, Ga
Greetings all, I just started a rebuild on a sweet Xd9000i. Tearing it down and evaluating now. Can’t wait to see where this takes me.. Anyone else running this winch??

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Zjohnsonua

SILVER Star
Joined
Feb 1, 2018
Messages
792
Location
Huntsville, Alabama
I've had one of these sitting in my shop for a few years and I'm finally getting around to fab'ing the mount and installing the thing. I'm interested in what you find once you open it up.
 

73fj40lc

SILVER Star
Joined
Sep 2, 2007
Messages
1,489
Location
South
 
 
Greetings all, I just started a rebuild on a sweet Xd9000i. Tearing it down and evaluating now. Can’t wait to see where this takes me.. Anyone else running this winch??

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I have two XD9000I that I have had for over 20 years. Great winches and even after hard use at times they have never let me down. I have rebuilt the one on my 40 and the one on my Z71 I haven't rebuilt it yet. I bought it new in 1993 and it is still going strong. :hillbilly:
 
Joined
Dec 20, 2019
Messages
2
Location
Ontario
I picked up a used xd9000i a while ago and it's on the front end of my Jeep JKU. When I first picked it up I ripped it apart and cleaned it up. I learned the hard way not to remove the brake from the drum without securing it so that it wouldn't unwind. Recently ripped it all apart again, replaced the brake, gaskets and re-greased it. I learned a lot about it. I found the service manual online and a couple of other online resources and videos. The service manual really helped out. The first time I didn't use ep moly grease so it made it too sticky to easily free spool. This time I cleaned all parts really well, used Klondike EP#2 Moly grease on all parts and as the service manual says, don't use grease on the outer side of the sliding gear, use a light machine oil otherwise free spooling can be a bear.

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Joined
Jan 1, 2020
Messages
2
Location
Mississippi
I hopefully am picking one up tomorrow very cheap and not sure of internal condition. But i know it needs a controller, and I plan to break it down and go through it. I have watched several YouTube vids and feel like I can do it , but my main question is where do y’all go for parts, and what parts do y’all replace seal wise when break y’all’s open? Thanks.
 
Joined
Dec 20, 2019
Messages
2
Location
Ontario
For parts I went to a local off road dealer as I try to give my business to the little guy, brick and mortar store rather than to the big box or online. If I do go online then there's always amazon or northridge4x4.com.

This is the gasket kit for the housing. Warn Winch Housing Gasket

I found the service manual here...https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=6&cad=rja&uact=8&ved=2ahUKEwiTrdmR8-TmAhXOBc0KHca-BsMQFjAFegQIARAC&url=https%3A%2F%2Fwww.rolo4x4.com.br%2Fmanual-4x4%2F26%2Fmanual%2B4x4.html&usg=AOvVaw0Tp6ng34Ydy9IFrT2jkTL_
 
Joined
Jan 1, 2020
Messages
2
Location
Mississippi
Thanks so much! I got the winch and it’s in better shape than I was expecting. Free spool worked good. Waiting on new batt cables and controller to try out the function.

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