Warn Wiches

[Zedman]

To try and keep things organised i thought I would start a new post re Warn winches rather than incuding it with my general new vehicle thread.

Just made a serious start on the much neglected Warn 9.5 thermo that was included with my new landy purchase.

I still have not figured out why anyone would have a fairly expensive winch wired in to the battery but not have ANY bolts holding it in place ( and no controller)

What has become immediatly evident is the fact that mine and maybe all Warns dont like water, every section bar the main reel the cable winds round has had water and grit in it, the motor is water damaged, the free spool release mechanism that allows you to pull cable out was full of grit and the solonoids have been affected but not looked at them very closely yet. ( and I think the previous owner probaly doesn't even own any tools and only bought a defender because some of his mates have them and thought it was like a normal car and he could just drive it about without having to fix and maintain it constantly)


If anyone has a guide they can link regarding renovation and rebuilding a warn winch it would be greatly appreciated, if not i will start posting pics and info as I go through sorting mine out, due to the state its in and with a little bit of help from other members it will hopefully turn into a fairly usefull post for anyone wanting to do the same thing, I think kingsomlin might be working on one so maybe even more input.

[Bo]

I agree with your comments about water, on the 9000 series there is no effective way to stop water traveling down the centre of the drum and in to the motor or gearbox. When I rebuilt mine I sealed as much as I could with silicone and filled all of the cavities with a good quality marine grease, about £5 a tub. Covers are available to keep the worst of the salt out over the winter but the only real answer is a regular strip down and clean.
You can download all Warn manuals in pdf format direct from Warn website.
http://www.warn.com/truck/winches/src/9.5ti.shtml
If the motor its self is shot, I would recommend you replace it with a Bow Motor.
http://gigglepin4x4-shop.co.uk/epages/eshop343529.sf/en_GB/?ObjectPath=/Shops/eshop343529/Products/Bow12

[kingsonlim]

Richard....when I stripped down mine a few days back, I've found the gearbox side drum seal had been chewed up and the grease in the gearbox had turned into mayo. So, I cleaned/scrapped off as much grease/mayo as possible to the gears, then soaked them in white spirit. Using a brush and old toothbrush, I managed to get rid of all the grease/mayo.

In order to free the clutch gear, you'll need to remove the clutch lever, then slowly tap the clutch gear back in, and using a screw driver, prise it out through the clutch lever slot. Repeat the several time to free the clutch gear out.

Below are a few Items I bought (still awaiting delivery) to complete the re-building of my winch.

http://cgi.ebay.co.uk/HA6-RTV-MARINE-SI ... 5b&afsrc=1

http://cgi.ebay.co.uk/LUCAS-OIL-RED-N-T ... c7&afsrc=1

http://cgi.ebay.co.uk/Winch-Replacement ... 48327fd17a

As Bo mentioned, re-pack the gears and gear box with the Marine grease, then use the marine silicone to cover any gap from winch drum to the motor and gearbox housing as well as gap on the clutch lever. I also use high temp gasket maker to replace the paper gasket that was there when they first manufacture it.

[Matthews]

I tend to buy Bow motors direct from David Bowyer himself , and yes the Bow 2's are impressive.
Matthew