Pullmaster M8 Series - Reassembly of Final Drive; Reassembly of Primary Drive

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SERVICE INSTRUCTIONS CONTINUED
316 REV.980601
REASSEMBLY
Thoroughly clean all parts. Use only new, well-greased O-rings and oil seals. Unless otherwise specified, torque
fasteners per BOLT TORQUE CHART as 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 104.
3) Press cable drum, item 500, into ball bearing, item 103, and secure with circlip, item 513.
4) Reassemble final planet hub assembly. Press needle bearing, item 323, into final 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 313.
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.
7) Gently insert end cover into final housing, item 100, and fasten with retaining ring, item 124.
8) 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. Press sungear stopper, item 344, into end of final sungear, item
340. Insert final sungear into planet hub, item 400, and fasten with circlip, item 343. Press needle bearing, item
423, into primary planet gear, item 420. 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.
2) Insert final sungear and primary planet hub assembly into cable drum. Rotate drum by hand until sungear
engages final planet gears and primary planet gears engage cable drum.
3) Press new, well-greased oil seal, item 531, into bearing flange, item 530, followed by journal bearing, item 706.
Install circlip, item 517, and new, well-greased O-ring, item 539, into bearing flange.
4) Fasten bearing flange, item 530, to cable drum, item 500, using six socket head capscrews, item 537.
5) Install new, well-greased O-ring, item 545, and Parker seal, item 543, into seal carrier, item 538. Install seal
carrier into opening of end housing, item 698, and press ball bearing, item 103, tight against seal carrier. Press
end housing, with seals and ball bearing, onto bearing flange. Fasten with circlip, item 535.