Winch clutch slipping?

[red02tj]

my new to me 9.5.

Installed the new winch plate and went to tension the line. While in free spool, I can pull out the line by hand, but if I engage the motor, the winch drum will spin both in and out.

If hold the line while in free spool and engage the motor to bring the line in, I can easily hold the line and the drum will free spin.

Also looks like a decent amount of wiggle in the clutch lever. Ive run the line in/out about 5 times and same thing.

Should the clutch fully disengage?

Lever https://share.icloud.com/photos/075JUeZ99oYsZfuZNdzYpQOiA

 

[Zorba]

Sounds like the sliding ring gear is stuck and/or something going on with the pawl on the inside end of the lever...

 

[John Cooper]

@tnjeepguy @Blackjack

Help my bud out!!

 

[tnjeepguy]

Not real clear on what it is doing. With in free spool the motor will just spin, as it sounds as if it is doing. With it engaged does it wind in and out ??

The teeth may be stripped inside the gear housing. Only way to tell is take the gear housing apart and see what is messed up. Good to clean and regrease anyway.

https://www.rocketcityrockcrawlers.com/forum/_topic11377.html ?? Help ?

 

[red02tj]

I spoke to Warn and showed them the video.

With in free spool the motor will just spin,

It appears the brake is dragging, in free spin. The drum will still rotate, but lightly enough I can easily hold the line while winching in and break tension. I didn't hear any gears grinding.

With it engaged does it wind in and out

Yep, and appears the brake holds.

Good to clean and regrease anyway.

They suggested I order the 82463 Lever Midframe kit for a new clutch lever washer and set screw. I also ordered some AeroShell Grease 64. Looks like I'll start with pulling and greasing the gears, new o ring, set screw and go from there.

 

[red02tj]

Waiting on parts and grease so I started cleanup. Some buildup and a touch of surface rust on the sliding ring gear, but overall looks pretty good.

 

[red02tj]

Bath 1 complete

Will let soak overnight and then hit with the nylon brushes.

 

[red02tj]

Based on how this looks, keep tearing down, or just finish cleaning the gears and repack?

 

[Zorba]

Based on how this looks, keep tearing down, or just finish cleaning the gears and repack?

View attachment 615795

You've got it torn down this far, you're almost there. I'd completely tear it down, there may be other "surprises" awaiting, or even if not, you'll have it all cleaned up and know what you have. Its not that hard to do...

 

[Blackjack]

I did not see it in the pics but was there a snap ring on the driveshaft?

 

[red02tj]

I did not see it in the pics but was there a snap ring on the driveshaft?

Yes sir, removed and stored with the case bolts.

 

[red02tj]

Clean.

 

[Zorba]

Clean.

View attachment 615991

That scrubbed up nice - mine was good, but not this good!

 

[red02tj]

Gearbox assembly vid for reference

 

[Zorba]

Gearbox assembly vid for reference

Brings back memories. At first I thought you'd forgotten the little sun gear, but upon a replay, saw you install it after all.

Now you get to do it again after greasing everything!

 

[red02tj]

Brings back memories. At first I thought you'd forgotten the little sun gear, but upon a replay, saw you install it after all.

Now you get to do it again after greasing everything!

Thats my reference video….but I did follow along to test. Just waiting on my grease delivery.

 

[Zorba]

Thats my reference video….but I did follow along to test. Just waiting on my grease delivery.

I did the same thing - by the time I was ready to re-assy, I wanted to make sure I remembered how to do it so I wasn't fumbling around with it with greased parts!

 

[red02tj]

is the new style lever supposed to fit the older 9.5 series? The groove where the set screw rides is in the opposite direction, wanting the lever to rotate towards the winch and it can’t clear the housing, vs the old style which rotates out.

Either way, I like the old style better and it will cleanup just fine.

 

[red02tj]

Old lever cleaned up nice.

Got the gearbox assembled and did a no tensions spool of the line all the way in. Gears didn’t explode and no strange noises.

FWIW there is still a bit of friction when I have it in free spool and a use the motor but the gears are cleaned and freshly greased. Motor side for another weekend.

 

[red02tj]

@Blackjack @tnjeepguy got one for you guys before try and respool my line with some load on it after my clean and regrease.

The clutch lever will goto freespool first try every time. When moving to engage, the lever moves easily but sometimes I need rotate the drum, kinda like backlash, before it engages. Once engaged, it powers in/out without issue.