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253 REV.980701
SERVICE INSTRUCTIONS CONTINUED
7)
Remove five friction plates, item 715, together with six divider plates, item 713, and inspect for damage or wear.
Plates should be flat and smooth. Plates should not show heat discoloration. Paper material on friction plates
should be intact and grooved. If any damage is detected, replace friction and divider plates as a set.
8) Remove brake spacer, item 712.
DISASSEMBLY OF FINAL DRIVE:
1) Remove drain plug, item 121, from end cover, item 120, and drain lubricating oil from final drive assembly
and cable drum interior. (To drain all of the oil out of cable drum interior, winch should be tipped to an angle
and filler plug, item 121, removed.)
2) Remove 12 capscrews, item 127, and 12 lockwashers, item 541.
3) Remove end cover, item 120, from end housing, item 100, and discard O-ring, item 123.
4) Check thickness of planet hub stopper, item 126, and sungear stopper, item 122, for excessive wear.
Replace planet hub stopper if less than .25 inch thick and sungear stopper if less than .21 inch thick.
5) Remove final planet hub assembly from hub of cable drum, item 500.
6) Inspect three planet gears, item 320, for damage or wear. If it is necessary to remove final planet gears,
extract 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 necessary.
7) Pull final sungear, item 340, out of cable drum assembly.
DISASSEMBLY OF PRIMARY DRIVE AND SECONDARY DRIVE:
For ease of working on the unit, set winch upright on final drive housing.
1)
Remove five hex capscrews, item 555, with lockwashers, item 553, from each side of both tie bars, item 556,
and remove tie bars from assembly.
2)
Remove 12 hex capscrews, item 537, along with lockwashers, item 541, from secondary housing, item 456,
by rotating brake housing until access hole is over top of hex capscrews. Brake housing, together with primary
and secondary planet hub assemblies, can now be lifted out of cable drum, item 500. Discard O-ring, item 539.
3) To disassemble secondary drive assembly, remove internal retaining ring, item 481. Secondary planet hub
assembly can now be pulled out of secondary planet housing, item 456.
4) Remove secondary sungear, item 490, from between planet gears, item 470. Inspect secondary planet hub
stopper, item 494, for wear. Replace if less than .16 inch thick.
5) If secondary planet hub stopper needs to be replaced, or if secondary planet gears, item 470, must be
removed, start by removing circlips, item 461. Secondary planet pins, item 460, can now be pressed out of
secondary planet hub, item 450. Remove secondary planet gears, item 470, along with thrust washers, item
471. Inspect needle bearings, item 473, and replace if damaged.
6)
Primary assembly may now be slid out of internal gear and inspected for wear or damage. If primary planet
gears, item 420, must be removed, remove circlip, item 411, from planet pin, item 410, and press planet pin
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.
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