Warn 9.5ti brake issue

LBarr2002

Well-Known Member
Joined
Nov 16, 2009
Location
SC
Any winch experts here?

The brake hasn't been working on my warn 9.5ti for a long time. I took it apart and literally poured the brake pieces out of the drum. The snap ring had come off the end. I reassembled the brake assembly and all looked good, so I put it back together. But, the brake still doesn't work. Anybody know how to fix it?

17823-a1fefa5560a8de01fe878856e2eb8fbf.jpg
 
Subbed for knowledge!
My slightly used 9.5ti (came off a mall crawler) won't pull a greasy string out of a cats ass, so will tear it all down shortly.
IIRC, I ran across a couple of posts regarding the brake when surfing about them...
 
I'm not a winch expert but it's all fun to learn about. I got curious so I started looking at exploded parts views, etc...

Then I found this, which makes it sound like the internal spring needs to be preloaded while reassembling, rather than just putting the parts back together:
Warn winch HS9500i re-greasing and brake assembly repair - Jeep Wrangler Forum

Sounds simple enough (and sounds plausible that this is the issue), but I'm not the guy putting a brake assembly back together so it's easy for me to armchair-mechanic it.....
 
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Fabrik8 said:
I'm not a winch expert but it's all fun to learn about. I got curious so I started looking at exploded parts views, etc...

Then I found this, which makes it sound like the internal spring needs to be preloaded while reassembling, rather than just putting the parts back together:
Warn winch HS9500i re-greasing and brake assembly repair - Jeep Wrangler Forum

Sounds simple enough (and sounds plausible that this is the issue), but I'm not the guy putting a brake assembly back together so it's easy for me to armchair-mechanic it.....
Click to expand...
Awesome, I'll give it a try. When I feel like pulling the bumper back off to get the winch out...
 
I tore it back apart today, saw exactly what the describe about turning it 180 before install, still doesn't work...
 
I read something else about tensioning the spring between the 2 cone pieces, not just turning the cam piece 180 degrees. But, they said too loose and it will slip, too tight and it will drag, and recommend buying a new brake assembly. I really don't want to do this again...
 
Same issue with an M8000. I tried putting those parts back together 3 times. Never worked. Bought a new assembly and it came in a complete unit and it worked!
 
LBarr2002 said:
Ordered a brake assembly from Clemson4wheel today...
Click to expand...

kulatpusu said:
wr can i buy this item
Click to expand...

clemson4wheel.com

Clemson 4 Wheel Center

Jeep, Truck, SUV accessories, parts & service. Bling for your new truck, hard core parts for your trail rig, and everything in between!
clemson4wheel.com clemson4wheel.com

Call them. Its probably not an inventory item on their website, but they are a warn service center. If the part is available, they should be able to get it.
 
jeepster1407 said:
Sounds good. I'm going to give it a shot. Thanks for responding.
Click to expand...
Still had the box sitting on my workbench.
20211108_164047.jpg


This is my old brake, but the way its packaged.
20211108_164032.jpg


It also comes with a new driveshaft and side drive gear. I debated replacing because it requires further tear down, but I did and it needed to be cleaned and regreased. This is the grease you're supposed to use.
AeroShell Grease 64 (formerly 33MS) Extreme Pressure Grease - 14 oz Cartridge Amazon product ASIN B01M8OQMOV
 
LBarr2002 said:
Still had the box sitting on my workbench.

This is my old brake, but the way its packaged.

It also comes with a new driveshaft and side drive gear. I debated replacing because it requires further tear down, but I did and it needed to be cleaned and regreased. This is the grease you're supposed to use.
AeroShell Grease 64 (formerly 33MS) Extreme Pressure Grease - 14 oz Cartridge Amazon product ASIN B01M8OQMOV
Click to expand...

I spoke with Clemson 4 wheel today. Turns out the brake rebuild kit has been discontinued. Warn still has a few in stock in Oregon for a hefty price of $240. I'm going to tear into my winch next week and see if I can figure out how to reassemble it correctly before I order the kit.
 
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