Yet another WARN 8274 rebuild

[jsuthey]

Hi all,just thought I would start my own 8274 rebuild.Mine is going to be more of a rattle can resto(That's what i called my 40 build).
I just took of the solenoid pack off and then the cable just this evening.I'm trying to document the process and have been taking some photos.

I want to get into the gear box but could not get the allen bolts off.I will search on this after I post this up.If anyone has some tips on getting the bolts off and getting it opened up that would be great.I have soaked them with some oil&wd40 and wire brushed.I just want to have a look in there and change the gear oil.Then it will get some paint and hopefully be mounted up on my homemade bumper soon.

Here are a few pics.from this eve.my 8 year old girl was helping and left me some kind of note on the work bench.Funny stuff.More to come.

 

[jsuthey]

Here's a few more pics.I will try and find the pics.when I first got the winch.Sort of going backwards but I want to get it all on one thread.

 

[jsuthey]

I am thinking that the cheapo allen wrench set that I was using was not enough torque and I need to get the right size regular allen and fit some sort of breaker bar or pipe on the end it and it should do it.I just don't want to strip em'.

 

[jsuthey]

Some more older pics.of when I first got the winch.

 

[flyer91]

I took mine all apart today.
I have all the upgrade/rebuild parts coming this week from Amazon, and a 4.5 HP, 20 splined motor from DB Electrical.
I'm still hunting for the upgraded brake pads. Anyone know where they can be ordered from?

I didn't take any pictures, but ..... I sort of wish I had because mine did not come apart anywhere as easy as many reported.

The spool was a bear to get out, I had to smack it a few medium blows with a dead blow hammer to get it to finally release.

The brake assembly was next and required a puller and a 'lot' of force to get it to come off the double keyed shaft.
I'd tighten up on the puller then smack the head of the puller with the dead blow, then tighten up more and repeat until it came off.

Then the bushing needed the same treatment, but I had to make up a puller (using my mill and lathe) because the smallest puller I had was too big for it's claws to fit under the bushing (next to the spring) and get any grip.

Once that was done the next ...... and most difficult thing, was removing the brake shaft itself.
It was reported in one of the YouTube videos that all that holds this in is the seal.
Well I got the seal out easy enough with a small screwdriver and just prying it out, but the shaft was still firmly held in place by the bronze bushing in the housing.
I could see the by rotating the cam a bit I could move the gear away from the bushing (into the housing) and by holding it from rotating, I gave the side of gear some hefty smacks towards the bushing ...... hard enough to cause me some pause (thinking something else was holding it like a circlip or etc.) and concern it might cause some damage, but it finally moved the bushing and shaft out of the housing.
I tried the 'prying with a screwdriver' suggestion that they showed in the video, but that was just 'not' happening, and I was afraid that I might actually crack/break the housing, so I decided to back up the gear and smack it with the dead blow.
After a number of smacks from the dead blow hammer the bronze bushing finally worked out of the housing, and my 8274 is now fully disassembled ...... less the cluster gear and shaft in the upper housing.

It is my understanding that you only remove the cluster gear and shaft if it's absolutely needed (doesn't move freely and/or has damaged teeth, etc.....) and if you do remove it, you use a drift punch and push the shaft out from the motor mount side, toward the the knob side.

On mine .... the end of the shaft on the knob side it swagged in with 4 square depressions around the hole in the housing were that end of the shaft can be seen.
I assume if one needed to remove that cluster gear you would just punch it out, opening up those square swagged tabs in the process, and then use a punch to swagged the shaft back in again (using fresh areas around the hole's edge) after reassembly. (???)

In any case, I don't mean to hog the thread ......... I wanted to add this information, as I didn't see it anywhere else, and I'm sure I'm not alone in mine not being as easy to get apart as the ones in some of the other threads were.

 

[Sully73FJ40]

I am going through all of this as well with two winches. I have just posted it in my fj40 build thread. On the shaft in the upper housing I took my two and another guys to a machine shop to gave them pressed out. I also am adding a drain plug and fill plug while they are at the machine shop. The 4 impressions are crimps. Anyways check out my fj40 build thread I took pictures of everything and it appears I am only a step or two ahead of you all.