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2) Discard O-ring, item 123, and inspect planet hub stopper, item 126, and sungear stopper, item 122, for
excessive wear. Replace planet hub stopper if less than .30 inch and sungear stopper if less than .21 inch
thick.
3) Remove final planet hub assembly from final housing, item 100.
4) Inspect three final planet gears, item 320, for damage or wear. If it is necessary to remove final planet gears,
remove circlip, item 311, and press planet pin, item 310, out of planet hub, item 300. Inspect loose rollers,
item 323, and two thrust washers, item 321, and replace if damaged.
5) To separate cable drum from final housing, first remove circlip, item 513. Insert two heel bars between the
flange of the cable drum and final drive housing and gently pry cable drum out of ball bearing, item 103.
6) Remove the internal retaining ring, item 104, to remove ball bearing, item 103. Remove and discard oil seal,
item 105.
REASSEMBLY
Thoroughly clean all parts. Use only new, well-greased O-rings and oil seals. Unless otherwise specified, torque
fasteners per BOLT TORQUE CHART at back of manual.
REASSEMBLY OF FINAL DRIVE:
Reassemble final drive end of winch as follows:
1) Press a new, well-greased oil seal, item 105, into final housing, item 100.
2) Press ball bearing, item 103, into final housing and secure with retaining ring, item 104.
3) Press cable drum, item 500, into ball bearing, item 103, and secure with circlip, item 513.
4) Reassemble final planet hub assembly. Use grease to temporarily hold 24 loose rollers, item 323, in the bore
of the planet gear, item 320. Position thrust washers, item 321, on either side of planet gear and press planet
pin, item 310, into the final planet hub, item 300. Retain with circlip, item 311.
5) Insert final planet hub assembly into final housing, item 100. Ensure that final planet hub spline is fully
engaged with cable drum, item 500.
6) Install a new, well-greased O-ring, item 123, into the end cover, item 120. Verify that planet hub stopper, item
126, and sungear stopper, item 122, are installed into end cover.
7) Gently insert end cover into final housing, item 100, and fasten with retaining ring, item 124.
REASSEMBLY OF PRIMARY DRIVE:
Turn winch over, resting on end cover with cable drum opening facing up. Reassemble primary drive as follows:
1) Press a new, well-greased oil seal, item 531, into bearing flange, item 530. Press ball bearing, item 533, into
bearing flange and secure with retaining ring, item 534.
2) Press bearing flange assembly onto brake housing, item 700, and install new, well-greased O-ring, item 539.
3) Press a new, well-greased oil seal, item 711, into bore of brake housing, item 700.
4) Press a new, well-greased oil seal, item 607, into bore of connecting shaft, item 600, followed by needle
bearing, item 603.
5) Slide brake hub, item 720, onto connecting shaft and secure with circlip, item 721. Place thrust bearing, item 617
(held between two thrust washers, item 615), against brake hub and slide connecting shaft into brake housing.
6) Place thrust bearing, item 435 (held between two thrust washers, item 433), onto internal gear, item 430, and
251 REV.970601
SERVICE INSTRUCTIONS CONTINUED
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