Outer Limits 4x4 Board

its a warn m8000.
and the stroy goes.....
after a dip in a muddy bog hole i found that the winch wouldnt freespool. the clutch handle was jammed. i figure this is pretty common coz ive read of a few blokes pulling them down and giving them a clean, so i did just that.

i pulled the gearbox apart, cleaned all the muddy grease out, repacked it with marine grease, reassembled it the way i pulled it out.

now, the clutch handle turns freely, however the drum doesnt rotate as easily as i remember. and when i power it up it makes a horrible noise, pulls a heap of amps and spins really slowoly. it doesnt matter if the clutch is in freespool or engaged position. it still spins.

ive pulled it down and reassembled it, checked the warn website and it appears i have reassembled it the same way they show on the website. i'm out of ideas, are there any winch guru's out there who may be able to shed some light on the situation???

cheers, Jordan.

i had a similer thing happen to my warn winch

turns out i after it pulled me out of a deep bog hole
i thrashed the bearings and the drum had a kink in it
i also had a few other issues but none related to what yours is doing

sadly for mine is was going to cost more to fix/rebuild than to buy a new one
so it ended up in the bin

You didn't pack too much grease in the gears that the motor cant turn it? They don't need heaps.????

i did think of that, so i took as much grease out as i cold. still no better. it shouldn't be bent because the winch ran fine after the bog hole, it was just after sitting there for a while the grease kinda turned into mud. ill keep trying i suppose.

It might have something to do with the break on the inside of the drum.
Might be in wrong and grabing on the drum????
Process of elimination

yep, thanks coogs. i was thinking about looking at that. i'll let you know how i go later tonight with it

yeah, I agree. sounds like your winching in while the brake is engaged. Sure you wired it up properly (didn't switch the wires so it winches in to the other side of the drum)?

Did you pull the brake out of the drum?

aaaah.
i can figure the gears out no probs. i'm 100% certain they are reassembled right.

as for the brake, i'm not so sure. its possible the brake is jammed. i pulled it apart and realligned those two pieces that cam together.
but this could all be wrong!!!

as for wiring, all i did was piss off the solenoid box, bridge the armature and one of the field windings together and applied positive to the other field winding. ive done this before and it worked no probs.
I'm a sparky so i shouldnt screw it up. Should I?????

I'll play around with the brake some more and see if i can fix this damn thing.

fixed it.

i played around with the brake and took some more grease out of the gears. think it may have been the grease.
you were right coogs they dont need much at all. ill remember that next time.

thanks for all your help.

the brake tension is pre-set at the factory and shouldn't be messed about with. If you need to remove the brake, slide it out the drum a little then put a cable tie around it to hold it all together.

thanks cossie but i'm afraid its a little too late for that. ill check it on a small alope and if it doesnt hold ill take it to a winch dr to set the brake im just glad it spins at the moment.