Posted by Dave (Sussex UK) on September 21, 1999 at 11:23:50:

In Reply to: Maintenance/cleaning of a WARN XD9000 winch. posted by Rui Nuno on September 21, 1999 at 06:06:10:

It's your lucky day!
At the weekend I was at the Belgium Nationals along with 299 other Land Rovers and Warn had a stand with a US sales guy and Swiss technician. Apparantly Warn use a 'grey' grease, described by the technician, and with a little prompting and interpretation this is a regular type of molybdenum grease used for automotive applications.
I use a M8000 on my truck and clean it about 4 times per year, although the design is different to your XD9000 the principles are the same. I have drilled and tapped a hole in the end face of the gearbox and screwed in a grease nipple. After off-roading I pump some grease in to expel any dirt or water. You need to dismantle the complete unit, clean out all traces of debris and old grease from the gearbox, re-grease and assemble. Running through the centre of the drum is a hexagonal section rod (on my M8000 and almost definitely on your XD 9000). On the motor side of the drum, inside the bore, there are 3 moulded plugs (120 deg segment) that form the brake. Mud and rust get in here and can overload the motor because the brake sticks on, motor gets hot, NO WINCH!
BE CAREFUL. Make careful note of the relative positions of the spring, clips and brake parts. They must be re-assembled correctly.
Clean all these parts, use scotch-brite to clean the flanges of the drum and an abrasive flap wheel inside the drum to clean off all rust and debris. There is a nylon sleeve at each end of the drum which act as bearings (if not broken). I asked the technician why Warn insist on using carbon steel without any corrosion resistance for the drum: Answer cost! My reply why should I bother buying another Warn!
Assemble all parts with a liberal coating of grease and don't forget the grease nipple! By the way my local Warn dealer in the UK has plenty of spare parts, so if your from US should be no problem. Most used spares are the nylon sleeves at the drum ends, a nylon sleeve in the gearbox and the screw with holds the cable ferrule onto the drum.
Have fun
Regards Dave.
dc@cirrus-laser.co.uk

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