PAGE 22 323 REV.030624
remove circlip item 311, and press planet pin item 310, out of planet hub item 300. Inspect loose rollers item
323, bearing spacers item 322, and two thrust washers item 321, and replace if necessary.
8) Pull final sungear item 340, out of cable drum item 500.
9) Remove 8 socket head capscrews item 207, along with lockwashers item 217, from spring retainer item 212.
CAUTION: Since 99 springs apply pressure behind spring retainer, socket head capscrews should be
loosened one turn at a time, until spring pressure has been relieved.
10) Pull spring retainer item 212, out of end cover item 240. Remove and discard two O-rings item 213, from
spring retainer.
11) Remove 99 springs item 232, from clutch piston item 230.
12) Pull clutch piston item 230, out of free fall housing item 200. (Use two long 5/8-11NC capscrews screwed
into piston to assist removal. Alternatively, compressed air may be carefully applied to free fall release port
to assist removal of clutch piston.)
13) Remove and discard O-rings items 231 and 213, from clutch piston.
14) Check clutch piston outside diameters and inside diameters of end cover for surface scratches due to
contamination resulting from particles in the hydraulic fluid. If there is any evidence of surface damage, polish
with fine emery cloth.
15) Pull clutch connecting shaft item 220, out of end cover, along with bearing item 221.
SERVICE INSTRUCTIONS CONTINUED
16) Remove 10 friction plates item 206, together with 11 divider plates item 204, and inspect for damage or wear.
Plates should be flat and smooth. Plates should not show heat discoloration. Paper material on friction plates
should be intact and grooved. If any damage is detected, replace friction and divider plates as a set.
17) Remove clutch spacer item 202.
DISASSEMBLY OF PRIMARY DRIVE AND SECONDARY DRIVE:
For ease of working on the unit, set winch upright on final drive housing.
1) Remove five hex capscrews item 555, with lockwashers item 553, from each side of both tie bars item 556,
and remove tie bars from assembly.
2) Remove 12 hex capscrews item 537, along with lockwashers item 541, from secondary housing item 456,
by rotating brake housing until access hole is over top of hex capscrews. Brake housing, together with
primary and secondary planet hub assemblies, can now be lifted out of cable drum item 500. Discard O-ring
item 539.
3) To disassemble secondary drive assembly, remove internal retaining ring item 481. Secondary planet hub
assembly can now be pulled out of secondary planet housing item 456.
4) Remove secondary sungear item 490, from between planet gears item 470. Inspect secondary planet hub
stopper item 494, for wear. Replace if less than 0.16 inch thick.
5) If secondary planet hub stopper needs to be replaced, or if secondary planet gears item 470, must be
removed, remove circlips item 461. Secondary planet pins item 460, can now be pressed out of secondary
planet hub item 450. Remove secondary planet gears item 470, along with thrust washers item 471. Inspect
needle bearings item 473, and replace if damaged.
6) Primary assembly may now be slid out of internal gear and inspected for wear or damage. If primary planet
gears item 420, must be removed, remove circlip item 411, from planet pin item 410, and press planet pin
DAMAGED FRICTION OR DIVIDER PLATES WILL REDUCE BRAKING CAPACITY AND ALLOW THE LOAD TO
DROP, CAUSING PROPERTY DAMAGE, SEVERE INJURY OR DEATH. SOLVENT MAY DAMAGE THE
FRICTION PLATES. DO NOT USE SOLVENT TO CLEAN THE FRICTION PLATES. PERFORM THROUGH
INSPECTION AND, IF NECESSARY, REPLACE FRICTION AND DIVIDER PLATES AS A SET.
DANGER
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