10
SERVICING THE BRAKE
1. Evenly remove the four capscrews (Item 41) holding the brake cover in place. Spring
pressure will raise the cover up as the capscrews are loosened. Remove the cover from the
brake housing.
2. Remove the springs (Item 21) from the piston and check them for free height. Each spring
should measure at least 1.200 inches with no force on them.
3. Remove the brake piston (Item 10) by installing two pieces of 3/8"-16NC all-thread in the
bottom of two spring pockets. Using jam nuts, screw the all-thread pieces in evenly until the
piston is clear of the housing. An alternate way of removing the piston is to use a portable
power unit or air to slowly pressurize the brake cavity and blow the piston out of the bore.
4. Grasp the brake driver/clutch assembly (Item 34) and remove it from the brake housing.
5. Remove the stator plates (Item 17) and friction discs (Item 16) from the brake housing and
check them for excessive wear. Replace if necessary. Be sure to check the top stator plate
for scoring caused by the removal tools and polish if necessary. Friction discs should
measure no less than 0.055 in. thickness and stator plates should measure no less than
0.068 in. thickness.
6. With a hook wire or pry bar, remove the seal (Item 33).
7. Examine the bushing (Item 35) in the brake housing for wear and, if worn, replace it.
8. If brake housing (Item 18) is removed from winch, examine the journal on the brake housing
where the seal (Item 22) runs for wear. If severely worn, replace the brake housing.
9. Carefully dis-assemble the brake driver/clutch assembly noting the direction of lockup for the
clutch (Item 31). The clutch assembly must be re-assembled with the arrow pointing in the
proper direction for the winch to function properly. Inspect the surface on the brake driver
(Item 11) where the clutch (Item 31) runs. If there is any pitting or spalling on the driver, then
it and the clutch must be replaced.
10. Re-assemble the driver/clutch assembly, making sure that the clutch is installed properly.
11. Install a new seal (Item 33) into the brake housing, If brake housing is removed from the
winch, temporarily install the input sun gear into brake housing, and slide the driver/clutch
assembly onto the sun gear spline.
12. Install the stator plates (Item 17) and friction discs (Item 16) into the brake housing starting
with a stator and alternating friction discs and stator plates. There is one more stator plate
than friction disc so you will finish with a stator plate.
13. After installation, check the brake stack up to make sure that the dimensions are within the
tolerance shown on (Fig. 9). If your measurement is greater than shown, either some friction
discs and stator plates have been left out, or the friction discs are worn beyond acceptable
tolerances. If your measurement is less than shown, too many plates or discs have been
inserted or they are not seated properly.
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