PAGE 15
should be intact and grooved. If any damage is detected, replace friction and divider plates as a set.
7) Remove brake spacer, item 712.
8) Remove the drain plug, item 121, from the end cover, item 120, and drain the lubricating oil from the final drive
assembly and the cable drum interior. To drain all of the oil out of the cable drum interior, the winch should
be tipped to an angle, and the filler plug, item 503, removed.
DISASSEMBLY OF PRIMARY DRIVE:
For ease of working on the rest of the unit, set the winch upright on the final drive housing.
1) Remove the two winch base halves, item 550 and item 552, by removing the 28 hex capscrews, item 551,
and lockwashers, item 553.
2) Remove the access plug, item 734, using a 1/2-13NC bolt (motor adaptor bolt, item 821, works nicely), from
inside brake housing and discard O-ring, item 735.
3) Remove six hex capscrews, item 537, with lockwashers, item 541, from bearing flange, item 530, by rotating
brake housing until access hole is over top.
4) Lift brake housing, together with the bearing flange and primary planet hub assembly, out of the cable drum,
item 500, and discard O-ring, item 539.
5) Remove final sungear, item 340, from cable drum.
6) Remove retaining ring, item 401, and remove primary planet hub assembly from inside the internal gear, item 430.
7) Inspect three primary planet gears, item 420, for damage or wear. If it is necessary to remove primary planet
gears, remove circlip, item 411, and press planet pin, item 410, out of planet hub, item 400. Inspect loose
rollers, item 423, and two thrust washers, item 421, and replace if damaged.
8) Remove primary sungear, item 440, from center of connecting shaft, item 600.
9) Remove circlip, item 431, and internal gear, item 430, from connecting shaft spline.
10) Remove and inspect two thrust washers, item 433, and thrust bearing, item 435. Replace if cracked or
otherwise damaged.
11) The connecting shaft, item 600, can now be pulled out of the brake housing. Remove and inspect two thrust
washers, item 615, and thrust bearing, item 617. Replace if cracked or otherwise damaged.
12) Remove needle bearing, item 603, inspect and replace if damaged.
13) Remove and discard oil seal, item 607, and if present, backup washer, item 606, from inside of connecting
shaft.
14) Remove and discard oil seal, item 711, and if present, backup washer, item 710, from bore of brake housing.
Inspect two needle bearings, item 605, and replace if necessary.
15) To separate bearing flange, item 530, and brake housing, item 700, use a standard bearing puller or insert
two heel bars in the slot between the bearing flange and the brake housing and pry brake housing out of ball
bearing, item 533.
16) Remove the internal retaining ring, item 534, to remove the ball bearing, item 533. Remove and discard oil
seal, item 531.
DISASSEMBLY OF FINAL DRIVE:
Stand winch on cable drum flange with final end up and disassemble as follows:
1) Remove the internal retaining ring, item 124, and pull the end cover, item 120, out of final drive housing, item 100.
251 REV.970601
SERVICE INSTRUCTIONS CONTINUED
To Next Page
Loading...