Bought this Warn XD9000i for less than a ton:
Main obvious problem was that the clutch lever for the free spool was missing, you can see that the area of housing is damaged where the detent screw fits for the lever. So I've ordered a new housing assembly which comes with lever and gaskets from Devon 4x4.
Removed the 10 allen bolts holding the gear assembly to see what state the planetary gears were in - first impression was that the grease was very hard but what I could see of the gears looked good:
Hex shaft and 'drive spline' look good but again gummed up with old grease:
Top cover off and the solenoids are in amazingly good shape:
Disassembled the gear assembly and cleaned off the excess grease - all the gears operate well and there's no damage (had some lubrication for me too):
Got the motor housing cover off after a fight, the long bolts that hold it on were in a state and took some extracting, the cover itself needed lots of tapping with a rubber mallet to free it up. A whole pile of grey crap came out - looks to be remnants of dissimilar metal corrosion from the motor end cap:
The bearing that sits on the end of the motor shaft next to where the brushes contact is siezed:
The end cap itself is very corroded:
The winch came with this isolating solenoid which I may reuse.
The two lower allen bolts that hold the end plates to the bottom tray of the solenoid pack are completely seized in by dissimilar metal corrosion and have rounded, so out came a large drill bit.
Got the drum off and knocked the motor out of the end plate, it was pretty solidly in the bearing...
Degreased all the planet gears using gunk and white spirit, then gave them a healthy coating of light oil to inhibit rusting...
Next job is to repaint.
TBC
