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SERVICE INSTRUCTIONS CONTINUED
out of primary planet hub item 400. Remove primary planet gear item 420, together with loose rollers item
423, and thrust washers item 421.
7) Remove primary sungear item 440, from centre of connecting shaft item 600.
8) Remove circlip item 431, from end of connecting shaft and slide internal gear item 430, along with bearing
stopper item 532, off of connecting shaft spline.
9) Connecting shaft item 600, may now be pulled out of brake housing, and O-ring item 601, discarded. Inspect
needle bearing item 603, and replace if necessary.
10) To separate secondary housing item 456, and brake housing item 700, use a standard bearing puller or insert
two heel bars into slot between secondary housing and brake housing and pry brake housing out of spherical
roller bearing item 533.
11) Remove internal retaining ring item 534, to remove spherical roller bearing item 533. Remove and discard
oil seal item 531.
12) To separate final drive housing item 100, and cable drum item 500, first remove external circlip item 513,
off end of cable drum, then insert two heel bars into slot between final drive housing and cable drum and pry
out of ball bearing item 103.
13) Remove 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. If the entire winch was disassembled, start by
reassembling the free fall end first.
REASSEMBLY OF FREE FALL ASSEMBLY:
Reassemble free fall end of winch as follows:
1) If free fall housing was removed, press in new oil seal item 105, and bearing item 103, if removed. Re-install
retaining ring item 109.
2) Press free fall housing item 200, onto splined end of cable drum, and install circlip item 513.
3) Set end cover item 240, with opening facing up.
4) Install clutch connecting shaft item 220, into end cover.
5) Set clutch spacer item 202, into end cover, and place a divider plate item 204, against it, lining up teeth with
those inside of end cover.
6)
Place brake plate item 206, against divider plate, lining up teeth onto teeth of clutch connecting shaft item 220.
Alternate remaining divider and brake plates, finishing stack with a divider plate.
7) Install new, well-greased O-rings item 231 and item 213, onto clutch piston item 230.
8) Carefully press clutch piston item 230, into end cover item 240. If a hoist is available, piston can be supported
using two 5/8 -11NC eyebolts.
9) Place 99 springs item 232, into holes in clutch piston.
10) Install two new, well-greased O-rings item 213, into grooves on flanges of spring retainer item 212.
11) Fasten spring retainer to end cover using 8 socket head capscrews item 207, along with 8 high collar
INCORRECT ASSEMBLY OF THE FRICTION PLATE AND DIVIDER PLATE STACK WILL
REDUCE BRAKING CAPACITY AND ALLOW THE LOAD TO DROP, CAUSING
PROPERTY DAMAGE, SEVERE INJURY OR DEATH. REASSEMBLE PER INSTRUCTIONS.
DANGER
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