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How hard is it to rebuild one of these things?

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How hard is it to rebuild one of these things?
Buuushman

Buuushman

Senior Jeeper
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Location
Kihei, Hawaii
Vehicle(s)
77' CJ-5, 360 c.i. motor, T-176 trans, D-300 transfer case w\ twin sticks, Dana 30 front, A.M.C. 20 rear w/ 4.10's, solid axles & trac-lok, 2.5" lift Y.J. springs.
Found a old warn winch on C.L.- may offer $50 if it's not to much of a pain to rebuild-
Warn Winch For Sale


Thanks- Bush
 
They are not hard to work on (at least mine wasn't, but it's a different model).
The big thing is the price of new parts from warn.:eek:
If I was you I would check out there web site for prices of parts you may need. If the motor is shot your talking some bucks.
 
Well the #'s shown on the ad are off the motor so they do me no good in identifying it to even look up parts prices so I'm kinda stuck. I don't see the remote either and not sure how the engage - disengage works on it- don't see a handle. Waiting on a callback for more info if there is any.

Thanks for the reply Old Dog
Bush
 
Buuushman said:
Well not sure how the engage - disengage works on it- don't see a handle.
Bush
Click to expand...

thats strange, I've never seen a winch without one.:confused:
 
it has the mounting plate, and fairlead roller, i would say it is worth it. That is an older model, and i would guess that getting a closer look would tell you more.
 
They aren`t that bad to rebuild, been looking for one myself. looking at the tag in pic it almost looks like it says M41?? above the 45365 kc4, but i`m unable to find a good reference. only one mention of a kc4 and it was a 12,000lb. Get more info and i`ll dig somemore.
 
I sent pics to Warn and the rep. said it was an 84 m6000 or m8000. They don't make parts for it anymore and the guy already told me it doesn't work and there's no remote for it. I was still gonna give the guy $50 for it just to see if I could get it working but he thought I was lowballing him and got ticked. I'm sure he'll find a sucker to give him the $100 for it but it wont be me.

Thanks for the help braddahs,

Bush
 
I find it ammusing that warn has a life time warranty yet they no longer make parts for it.:rolleyes: Whats up with that.
 
I'm sure you can upgrade to a newer model solenoid pack and controls and get it to work but with the prices of new winches coming down the way they are, It's just not worth it to me. It will probably need new brushes and brakes too. I just thought it was old school lookin' and matched my Jeep so I was willing to give it a shot. I'll keep lookin'.

Bush
 
Well the guy decided to sell it to me for $50- so I grabbed it. I am hoping I did not just buy a boat anchor. The guy showed up in a stock 4 door Jeep- with the doors removed- and his leg hanging out- I did not know whether to puke or kick him in his A-hole. It is a '84 Warn M6000. I found the old style solenoids on flea-bay out of Australia, @ $80 for the set of 4, and a remote looks like it will run about the same price.

A few questions,
Should this thing freespool? It has a flat plastic knob that turns but the drum won't budge.
If I tear it apart, what should I watch for? Parts flying out etc.
Can it be retrofitted with newer controls without too much hassle?
Where do I start?

Thanks,

Bush

warn1.webp

warn2.webp

warn3.webp
 
you will have to look to confirm but are the solenoids in that just Ford starter solenoids?? and I bet you got some where on the island that rewinds starter motors. :cool:
It is just a reversible starter motor
 
Warn has some exploded views on there web site you can download.
even if they no longer have yours you might look at some otheres for ideas.
Here's some pics of mine from a thread awhile back, maybe it will give you some ideas even though its a different model..http://www.jeep-cj.com/forums/f71/winch-rebuild-4325/
I didn't have anything come flying out at me, but as always pay attention to how it comes apart and you should be good.
 
I read on another site that starter solenoids are not meant for constant current and will fuse together under load- dunno if that is B.S. or not but a winch stuck in retrieve does not sound like fun. If that is B.S. I'd like to know cuz that sounds like a easy fix on the solenoids.
 
even if it is true, I bet the solenoids are available from Warn even if they quit making that model. They sure look like ford solenoids.:cool:

Buuushman said:
I read on another site that starter solenoids are not meant for constant current and will fuse together under load- dunno if that is B.S. or not but a winch stuck in retrieve does not sound like fun. If that is B.S. I'd like to know cuz that sounds like a easy fix on the solenoids.
Click to expand...
 
you can use the solenoids from an 8274 or the later model 8274-50 there are no differences in the solenoids. my 83 model 8274 has the exact same solenoid pack on it. if you look around you'll find replacement motors fairly cheap, i found a 4.5hp motor for mine for around $75 at a place called db electric Starters, Alternators and more for Cars, Trucks, Tractors and ATVs they also have the solenoids for em.
in all honesty i think you can use the ford solenoids they just want you to buy their more expensive ones. i'll tell you why i think this, alot of people that run hydraulics on cars use the same solenoids on pumps, they also use em on air compressors. i have 4 of em on my boat two for the trim pump, one for the starter and one for main power off/on. and yes the ones for the trim pump are ford solenoids i put em on there myself, not a problem yet.
 
Sounds good, I think I'll give the Ford solenoids a shot- gotta do this on the cheap and I was gonna use a kill switch (like on racecars) so if it fuses I can shut the whole thing off. I pulled the gear assy. off and besides the lack of grease all the gears look good and the motor is not frozen. The brush plugs are stuck in the housing so getting the motor apart is gonna be a chore, but I'm feeling a bit more optimistic about the rebuild. This is gonna take a few beers.

warn gears.webp

warn end.webp
 
in the second pix, that is the brake, if it's froze thats why it won't freespool. That was the same problem mine had. When the shaft turns either direction it should disengage. I had to use a hammer and bump mine out, and than clean the rust out of the bore in the spool. It works now.
One other thing I discovered was go easy on the greese, it works better with only enough to coat the gears, I packed the gears with a lot of grease and it was real stiff, took it back apart and removed most of the grease and it free spooled a lot easier.
 
Well, I lied- the motor is locked up tighter than a (something I cain't say). I've got it sprayed down with penetrant so we shall see tomorrow if I can get it apart and salvage it. If it is truly dead, we do have a starter\ alternator rebuilder in town, I'll see what they can do with it.

Many Mahalos everybody.

Bush
 
They make electric cleaner sold at most parts stores I drowned the last one I poked at and it cleaned up nicely.
We use those ford solenoids for taurus fan installs and you know what kinda power they drain.
 
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