Pullmaster M8 Series - Page 133

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SERVICE INSTRUCTIONS CONTINUED
240 REV.951201
10) To separate the final drive housing, item 100, and cable drum, item 500, first remove the external circlip, item
513, off the end of the cable drum then insert two heel bars in the slot between the final drive housing and the
cable drum and pry the cable drum out of the ball bearing, item 103.
11) Remove the internal circlip, item 109, to remove ball bearing, item 103. Remove and discard oil seal, item 105.
The PULLMASTER Model M18 has now been completely disassembled.
REASSEMBLY
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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 circlip, item 109.
3) Press cable drum, item 500, into ball bearing, item 103, and secure with circlip, item 513.
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4) Reassemble final planet hub assembly. Use grease to temporarily hold 22 loose rollers, item 323, in the bore
of the planet gear, item 320. Position thrust washers, item 321, on either side of planet gear and press planet
pin, item 310, into the final planet hub, item 300. Retain with circlip, item 311.
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5) Insert final planet hub assembly into final housing, item 100. Ensure that 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.
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7) Gently insert end cover into final housing, item 100, and fasten with retaining ring, item 124.
8) Temporarily remove breather relief valve, item 130, from end cover. Turn winch up on end with cable drum
opening upwards.
REASSEMBLY OF PRIMARY DRIVE:
Reassemble primary drive as follows:
1) Reassemble primary planet hub assembly. Use grease to temporarily hold 20 loose rollers, item 423, in the 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 final planet hub, item 400. Retain with circlip, item
411.
2) 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.
3) Press bearing flange assembly onto brake housing, item 700, and install new, well-greased O-ring, item 539.
4) Press new, well-greased oil seal, item 607, into bore in connecting shaft, item 600. If a backup washer, item
606, is included in seal kit, install it behind oil seal.
5) Install new, well-greased O-ring, item 601, onto connecting shaft and insert through bore of brake housing, item
700. Place spacer, item 434, onto shoulder of internal gear, item 430, and slide internal gear onto spline of
connecting shaft. Fasten with circlip, item 431.