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240 REV.951201
SERVICE INSTRUCTIONS CONTINUED
8) Remove brake spacer, item 712.
9) The oil seal, item 607, which seals the brake housing from the cable drum interior, can now be removed and
discarded. Remove and discard backup washer, item 606, if used in winch. (Replacement backup washer not
required unless included in seal kit.)
All parts have now been removed from brake housing and there is no need for further disassembly unless a
failure has been analyzed in the remaining winch assembly. If continuing, remove pipe plug, item 121, from the
end cover, item 120, and tip winch to drain lubricating oil from inside of the final drive housing and cable drum.
DISASSEMBLY OF FINAL DRIVE:
1) Remove retaining ring, item 124, and pull end cover, item 120, out of final housing, item 100.
2) Discard O-ring, item 123, and inspect planet hub stopper, item 126, and sungear stopper, item 122, for
excessive wear. Replace 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) Remove final sungear, item 340, from cable drum, item 500.
DISASSEMBLY OF PRIMARY DRIVE:
If primary drive requires service or repair, proceed as follows:
1) Turn winch over to sit flat on end of final housing, item 100. Remove four hex capscrews, item 555, with
lockwashers, item 553, from each side of both tie bars, item 556, and take the tie bars from the assembly.
2) Using a 1/2 inch capscrew, item 821, pull out access plug, item 734, out of the brake housing, item 700, and
discard O-ring, item 735.
3) Remove eight hex capscrews, item 537, along with lockwashers, item 541, from bearing flange, item 530, by
rotating brake housing until access hole is over top of them. The brake housing, together with the primary planet
hub assembly, can now be lifted out of the cable drum, item 500.
4) Remove internal retaining ring, item 401, from inside of internal gear, item 430. The primary planet hub assembly
may now be slid out of the internal gear and inspected for wear or damage. If the primary planet gears, item
420, need to be removed, take off circlip, item 411, from planet pin, item 410, and press the planet pin out of
the primary planet hub, item 400. Remove the primary planet gear, item 420, together with loose rollers, item
423, and thrust washers, item 421. On reassembly, these thrust washers must be installed.
5) Remove primary sungear, item 440, from center of connecting shaft, item 600.
6) Take circlip, item 431, off the end of the connecting shaft and slide the internal gear, item 430, along with spacer,
item 434, off of the connecting shaft spline.
7) The connecting shaft, item 600, may now be pulled out of the brake housing, and O-ring, item 601, discarded.
Inspect needle bearing, item 603, and remove and replace if necessary.
8) To separate the bearing flange, item 530, and brake housing, item 700, use a standard bearing puller or insert
two heel bars in the slot between the bearing flange and the brake housing and pry the brake housing out of
the ball bearing, item 533.
9) Remove the internal circlip, item 535, to remove ball bearing, item 533. Remove and discard oil seal, item 531.
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