Warb 8200 Winch Rebuild

im not sure where to put this so thought here was as good as any

I recently acquired a 1974 warn 8200 winch, this winch is the bridge model that sits snugly between the Belleview and warn 8000s and the 8274.





As you can see from the pictures the casing is much like the 8000s square and chunkey but the nice thing about this is that it has some of the features used on the later 8274s evidently warn were testing these for the fourth coming warns.
brake assembly and the motor closer to the later 8274s I mean it is power in/out and free spool unlike the earlia warns and bell views which were power in only. Or power in/put with no free spool
The winch I have is in fully working condition but bit tatty and in need of a bit of tlc. I though a fully working one would be the best place to start at least I no its good before I take it apart it also makes easier to diagnose any problems that arise and everything is likely to be superficial.

My intention it to give it a new lease of life by stripping it down giving it a nice lick of paint and replacing all the bushes bearings and seals.
Hoping to get the motor refreshed too if I can get hold of the brushed/other bits needed. As its all working now just a clean/grease and a lick of paint might be enough. Will have to play this bit by ear

Nice,

I was going to buy one of these as a cheaper alternative to an 8274 but as parts are obsolete i decided against it.

There a much better looking winch in my opinion though. Could you buy another one to use for parts?

Exactly why I went for one way way under 1/2 of the price of a scrappy second hand one. And built like a tank!

I am in a fortunate position where I have access to lathes and milling machines so nocking up another shaft etc is strate forward only bits are a bit more trickey are the gears but there are place a u can still get bits for them and there is a motor swap that is possible too a modern one off need be. most of the rest like bearings bushes etc are available through local people

I really enjoyed rebuilding my XD9000i, g'luck and keep the photo's flowing!

not really got much done on this tbh to many other things going wrong with my disco including my other winch tmax 10,000 deciding it didnt want to work any more one of the terminals on the motor is lose and i dont thing it makes a good contact i striped it down last year and rebuilt it after a similar issue but a different terminal.

what i have done for now is remove the tmax and an planning to "service" this warn 8200 in the coming weeks however it is about two inches too tall for my winch bumper so goign to have to modify that too

and on top of that i have a transfer box to do

I might clone my vehicle thread on here from another forum later, complete winch rebuild in there which _might_ be useful but it's pretty much just following this guide -> Warn xd9000i Winch Rebuild Obviously it's a completely different beast.

I saw one of the 8000's for sale on FB a while back and almost got it as it was 1/2 the price but he was claiming it was a 8274!? The motor end was different to yours but the other end was the same.

hahah i nearly brought that on too the bloke was a total Cu**
I arranged to go collect it 1/2 way across the country and then it turned up on ebay and sold for less than i was offering him next thing he came back to me and wantine me to come and collect it i told him where to go and got him banned from the fb page for mucking people about
thats really not on

still this one is in much better condition and i did pay a bit more for it lo but hay hoe

After saying id rebuild it i took it apart and there was nothing what so ever wrong with it it all looked mint so a a good clean, transfered my plasma rope over, a lick of paint and a freshly reworked bumper to take a winch SOOOOO much bigger and here we are i think it fits in there nicely.





Gave it a nice test pulling an another friends disco out off road and it pulls like a train so much better than my old Tmax 10,000 and a bazillion times quicker sounds a bit clunkey with the ratchet brake but once used to it im more than happy