PAGE 16
14)
Remove internal retaining ring, item 534, to remove ball bearing, item 533. Remove and discard oil seal, item 531.
15) Separate cable drum from final housing by first removing circlip, item 513. Insert two heel bars between flange
of cable drum and final drive housing and gently pry cable drum out of ball bearing, item 103.
16)
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.
REASSEMBLY OF FINAL DRIVE:
Reassemble final drive end of winch as follows:
1) Press 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 bore
of planet gear, item 320. Position thrust washers, item 321, on either side of planet gear and press planet
pin, item 310, into 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 new, well-greased O-ring, item 123, into 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.
f
REASSEMBLY OF PRIMARY DRIVE:
Turn winch over, resting on end cover with cable drum opening facing up. Reassemble primary drive as follows:
1) Press 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 needle bearing, item 603, into connecting shaft, item 600.
4) Install new, well-greased oil seal, item 607, with backup washer (if included in seal kit), item 606, into
connecting shaft.
5) Install new, well-greased O-ring, item 601, onto connecting shaft, item 600, and insert connecting shaft into
brake housing, item 700.
6) Slide internal gear, item 430, along with spacer, item 434, onto end of connecting shaft and fasten in place
with circlip, item 431.
7) Reassemble primary planet hub assembly. Use grease to temporarily hold 20 loose rollers, item 423, in bore
of planet gear, item 420. Verify placement of sungear stopper, item 444. Position thrust washers, item 421,
on either side of planet gear and press planet pin, item 410, into primary planet hub, item 400. Retain with
circlip, item 411.
8) Insert primary sungear, item 440, between three planet gears and insert sungear shaft into connecting shaft,
249 REV.960301
SERVICE INSTRUCTIONS CONTINUED
To Next Page
Loading...
