Winch (Warn 9.5TI) Not Engaging

[borkap]

I just bought a Jeep out of wisconson and is seems to be riddled with issues the latest of which is that when it got to me it didnt have a remote to the winch. The remote came today and the winch motor spins but the winch does not engage. I tried turning the handle both directions and still does nothing but spin up the motor. Is there something I am missing or something I ned to replace? I hope its not garbage... Worst case is there a rebuild kit for it?

 

[Black Bear]

Make sure the knob is actually engaging the winch. if not, the clutch may have issues. Warns are not hard to take apart.

 

[borkap]

I'll pull it out and check and if that doesnt work I'm gonna pull it off tomorrow and see what I can find out. I've seen some other posts where these things tend to break, but a 60 dollar part fixes it. I'll post up my findings.

 

[rockcreek84]

Some warns had a half moon key that holds the gear on motor shaft I have broken one spent 1.50 on new one slid it on and no problems

 

[borkap]

So I pulled it off today and tried to take it apart but I have 2 stuck allen bolts. I took of the cover of the right side where the engagment lever is. When I cracked it open water came out, but it all looked to be in working order and still well greased. I need to pull the motor off and look at that side but I gotta get these allen bolts out first. I looked at the exploded view on the warn site and I know there is stuff on the motor side but I cant seem to get it apart... Oh well I've had enough. Back at it in the AM.

 

[borkap]

Anyone in the charlotte area willing to give me a hand with this? I cant seem to get it apart and I am on the verge of destroying it...

 

[rockcreek84]

Is allens stripped or seized .

 

[borkap]

The bolts were seized. I soaked it in thrust for a couple days now. I stripped the allen bolt trying to get it loose. Then I hammered a torx bit into it and broke off the bolt... Keep in mind this rig came to me from wisconsin so everything is rusty it seems. Now my question is how to I get the three broken bolts out? They are currently soaking in even more thrust.

 

[rockcreek84]

Can try but most likely gonna have to drill out and retap. Not real familiar with that exact model but i live about 20 to 30 min away might can help work on it one day.

 

[borkap]

I'll go find the right bit and a tap set or helicoils after work. If you understand the guts of a winch I'll gladly make that drive.

 

[rockcreek84]

I have bits and taps. Will be in shop in evenings except wed. You can contact me by phone or text 704-202-9228.

 

[borkap]

Right on. I'm gonna give it a go tonight. If I can't get it apart ill be paying you a visit.

 

[rockcreek84]

let me know good luck

 

[borkap]

OK I went through three drill bits and they are still in there... Should I just take it to a machine shop or do you think you can get them out?

 

[rockcreek84]

Not sure but can try.

 

[borkap]

Well the machine shop turned me away. HAHA! I'm gonna call warn now and see how much it would cost to replace the parts if I smash it with a hammer.

 

[borkap]

Ok they are sending me parts I'm about to go apeshit on this...and no longer care about preserving the threads.

 

[borkap]

Got it apart and low and behold Warn support was spot on and its a sun gear thats broken.

 

[rockcreek84]

At least you don't have to buy new one. Good luck with it.