Outer Limits 4x4 Board

Hi all

I've decided to completely strip my Warn 8274 hi-mount. There are articles I've found out there with useful tips, but the authors don't respond when I try and ask a question of them. Primarily the bloke who wrote the article at: http://www.pirate4x4.com/tech/billavista/8274/

So, I've got it all apart down to the split gearbox case halves. I have the drum off, but am struggling with the brake disk (on the left in the photo). The circlip was a bugger, but once that's off, the disk assembly (3 pieces) os meant to literally "spring" off the shaft and let loose a bunch of ball bearings. Well - I can't budge it.



I've resigned myself to the fact that I'll have to get to wherever I can find a puller large enough to get it off without damage. Meanwhile, it looks like I can dissassemble the primary (lower) case and remove the gear sets. The drum drive gear at the bottom (and in the next photo at the bottom) is now loose after removing the drum. I'm wondering if anyone has taken one of these apart before, and managed to somehow slide the drake disk assembly, and the shaft that it's on, out to the left through the LHS housing and bearing set - and out through the large gear on the left in the photo.



Can this shaft come out that way at all? I don't want to damage anything by appying an inordinate amount of force. Any help would be mucho appreciated!

For those that are interested, images from the re-build are being posted on my site at: http://www.omaroo.net/index.php?set_alb ... _album.php


Cheers
Chris

I have pulled this assembly out before but can't remember exactly how I did it. There is a bronze bush which is a press fit, from memory, in the LHS of the bottom housing. This would need to be knocked/forced from the housing to get the assembly apart I think.

If you don't get the answer your after OM Lockee from on here and he'll tell you all you need know.

If you get the assembly out of the housing be careful when trying to pull/press the brake off the shaft as you may bend/buckle the plates.

Hope this helps

Thanks Fish

I've just had a look to see if that bush was obvious - but I can't see one anywhere. Does it protrude through the casing to the outside at all? Is it on the drum side or the clutch side?

Cheers
Chris

Sounds like the brake assembly is rusted on the shaft.

CRC it and then give it a light tap to remove the brake assembly.

The Steel plate that holds the drum in is the only thing that retains the shaft in place, this runs through a bronze bush and seal on the brake side. The drum side runs in a bearing.

Any problems let me know.

Remove the entire brake shaft before you pull it apart. It'll be easier. Place it loosely in a vice so the shaft is facing down, hold the drum together with a pair of vice grips and just give the shaft a bit of a tap with a soft hammer or use some wood between the drum and hammer, it should just pop out. To put this back together you just place all the pieces back together and hold them with vice grips. As stated above, to pull the brake shaft out you'll see a metal plate on the opposite end of the shaft just inside the gearbox housing. Simply lift this up and you can remove the shaft.

LOCKEE wrote:
The Steel plate that holds the drum in is the only thing that retains the shaft in place, this runs through a bronze bush and seal on the brake side. The drum side runs in a bearing.

Any problems let me know.

Lockee - I can see what you mean - i.e. the plate that held the drum in place has a larger aperture when you spin it around, and the shaft starts to slide out but is stopped by something about 6mm into the slide path. The plate clears everything at its end, and it's as though the bearing itself is holding it back from just sliding out. Is that bearing just an interference fit into to casing, as it might be easier to release the shaft along with that bearing?

Cheers
Chris

This will be the seal that is just behind the brake drum. Just use a bit more force being carful not to damage it and it will eventually pop out.

Thanks everyone for your help

I finally jiggled the outer brake assembly off, and now have the collar in the centre soaking overnight to see if it will budge tonight. Jeez - she's pretty corroded in there :(

Once that comes off I think it'll be easier to see what's what.