PAGE 15
SERVICE INSTRUCTIONS CONTINUED
2) Remove retaining ring, item 124, and pull end cover, item 120, out of final housing, item 100.
3) Discard O-ring, item 123, and inspect planet hub stopper, item 126, and sungear stopper, item 122, for
excessive wear. Replace sungear stopper if less than .35 inch thick and planet hub stopper if less than .14 inch
thick.
4) Remove final planet hub assembly from final housing, item 100.
5) Inspect three planet gears, item 320, for damage or wear. If it is necessary to remove planet gears, remove
circlip, item 311, and press planet pin, item 310, out of planet hub, item 300. Inspect needle bearing, item 323,
and two thrust washers, item 321, and replace if damaged.
6) Remove final sungear, item 340, from cable drum, item 500. Remove O-ring, item 293, from final sungear and
discard.
All parts have now been removed from the final drive assembly. If further disassembly is required, proceed as follows:
DISASSEMBLY OF CABLE DRUM ASSEMBLY:
To separate brake housing, item 700, and final housing, item 100, from cable drum, item 500, proceed as follows:
1) Remove 16 capscrews, item 971, and lockwashers, item 973. Remove two tie bars, item 970. Stand the winch
upright on its end housing.
2) Insert two heel bars between the flange of the cable drum, item 500, and the brake housing, item 700, and gently
pry the brake housing out of spherical roller bearing, item 507.
3) Remove and discard oil seal, item 515.
4) Inspect spherical roller bearing, item 507, and replace if damaged.
5) Turn winch over to stand upright on the drum flange. Remove circlip, item 513, from splined hub of cable drum,
item 500.
6) Insert two heel bars between the drum flange and the final housing and carefully pry the cable drum out of ball
bearing, item 103.
7) Remove and discard oil seal, item 105. If removal of ball bearing, item 103, is necessary, first remove circlip,
item 109.
The PULLMASTER Model M6 winch has now been completely disassembled.
REASSEMBLY
Thoroughly clean and lubricate 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 CABLE DRUM ASSEMBLY:
Reassemble cable drum assembly by reversing the disassembly procedure.
1) Press ball bearing, item 109, into final housing, item 100, and fasten with circlip, item 109.
2) Press new, well-greased oil seal, item 105, into other side of final drive housing.
3) Press final housing, item 100, onto hub of cable drum, item 500, and fasten with circlip, item 513.
4) Turn winch over so it stands on final housing end. Press spherical roller bearing, item 507, into cable drum, item 500.
5) Press new, well-greased oil seal, item 515, into cable drum, item 500.
184 REV.950201
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