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Warn Winch Rebuild

rattlewagon

rattlewagon

shitboxin
Joined
May 20, 2020
Member Number
552
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486
Loc
Northfield Vermont
This is an older thread posted else where, moving it here.

Bought this Warn XD9000i off a trailer dealer sight unseen in 2012 for $50

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Tested it, and of course it didnt work. All it would do is click.

Took the motor apart, the brushes were frozen. Cleaned everything and put it back together and it spins!

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Took the other side apart and regreased it too:

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I got a free cable from a friend with a broken winch, roller fairlead for $1 at a yard sale, spent about $25 on a hook, hardware, and electrical connectors, and it works!

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Made some cheap in cab controls. I used a extension cord with the ends cut off for the wires. Its 3 wires in a well protected jacket. and a trailer plug for a quick disconnect and switches from the local parts store.

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Picture from 4x4 wire on how to connect them, I followed their instructions. In Cab Winch Remote

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Used it just like that for many years.

Around 2016 one of the terminals on the warn motor broke off. I called warn, they wouldnt sell me motor parts, just new motors, at the tune of $300ish. I found a DB electric motor on line for $100 and gave it chance. It works awesome and is still pulling strong today.

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2019 I got some Ranger synthetic line off amazon and a hawse fairlead and thats still the setup Im running.

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Ive been very pleased with my old trailer winch.
 
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The hardest part when rebuilding these winches is getting the brake back together correctly if you pull the drum. It's doable but finicky.

I only paid $600 cdn for mine with a brand new 80 ft warn synthetic cable.

I'd like to wire mine for in cab controller too, or buy one of those wireless warn remotes that's prob a lot more clean install lol.
 
YotaAtieToo said:
That's a killer winch for what you have into it. I was not aware of the DB motor. I put the warn 9.5xp motor on my 8274 and holy hell :smokin:

Another point for going used warn over chicom stuff, parts availability down the road.
Click to expand...

I seem to recall 3 "levels" of motors for warns. A 2ish hp, a 4ish, and an 8ish. 2 choices, either splined or keyed...
When I was figuring which one I wanted, a buddy told me he had the biggest one on an 8274 with a contactor replacing the solenoids, it would reel in an additional 6-10 feet of extra line after you let off the controller. Momentum on the motor I guess? Even under load it would suck in a fair bit of additional line.
I went with a 4hp motor on mine and it was quick fast, but also stopped pretty reasonably.
 
The brushes and holder on that old warn motor look very similar to the ones I used in my thread on Chinese winch repair. I ran across those DB motors when trying to find a drop-in replacement for the plethora of mechanically identical chicom winches. Wonder how similar the drive types are between the Asian Warns and the better chicom winches. Don’t suppose you have any dimensions or good pictures of that? We’re all tightwads around here do there’s no broken warns to find to tear down:emb3:
 
Winchested said:
I'd like to wire mine for in cab controller too, or buy one of those wireless warn remotes that's prob a lot more clean install lol.
Click to expand...


On a friends runner, (the danger runner) We used this for his in cab controls but added switch for on/off too. This ones neat as it also adds a normal winch plug in the cab.

Amazon.com: WARN 99897 Lighted Dash Rocker Switch Kit : Automotive

Buy WARN 99897 Lighted Dash Rocker Switch Kit: Switches - Amazon.com ✓ FREE DELIVERY possible on eligible purchases
www.amazon.com

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IowaOffRoad said:
The brushes and holder on that old warn motor look very similar to the ones I used in my thread on Chinese winch repair. I ran across those DB motors when trying to find a drop-in replacement for the plethora of mechanically identical chicom winches. Wonder how similar the drive types are between the Asian Warns and the better chicom winches. Don’t suppose you have any dimensions or good pictures of that? We’re all tightwads around here do there’s no broken warns to find to tear down:emb3:
Click to expand...

Na thats all I have. I never took the DB motor apart, it just went right on.
 
I bought a FB Marketplace XD9000i for $300, while still a great deal, I didn't test it before buying it. When I got it home I put a jump pack on it to see if it worked, satisfied that it powered in and out, I didn't dive in any deeper. Fast forward a few weeks later when I got around to installing it, I discovered I couldn't disengage the planetary.

Pulled the gear box off of it, full of rust and corrosion, what little grease that was in it was rock hard. Took a gear puller to get the engagement ring gear out.

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Took a lot of PB Blaster, and a lot of time with a wire brush, but I got it freed up, and it works good now. Two of the gear box bolts broke while removing them. I wound up having to drill out and Heli-Coil one of them, replaced all the bolts with new, and went with RTV in place of the gaskets. I filled it with Lucas Red N Tacky, been great for 2+ years now.

I'd really like to freshen it up, give it a paint job, and put new decals on it. I've found several sticker/decal kits, but haven't been able to find Warn gray paint anywhere. Anyone have a paint code for Warn's gray? Know of a close match available in a rattle can, preferably an enamel.
 
Bringing this thread back from the dead with a question, where is everyone sourcing parts for Warn rebuilds.

I bought an M8000 that needs a new drum. It had a synthetic line on it that must have been stored wet a lot. The drum has some deep pitting. Everywhere I look is out of stock.
 
665.0coupe said:
Bringing this thread back from the dead with a question, where is everyone sourcing parts for Warn rebuilds.

I bought an M8000 that needs a new drum. It had a synthetic line on it that must have been stored wet a lot. The drum has some deep pitting. Everywhere I look is out of stock.
Click to expand...

Did you call warn?

EDIT: or is this it? (I googled it) WARN 26107 Winch Drum, VR Series, XD, M8000, other fitment in listing

That also listed a replacement part# 98767 which had a bunch of results when I put it into google.
 
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rattlewagon said:
Did you call warn?

EDIT: or is this it? (I googled it) WARN 26107 Winch Drum, VR Series, XD, M8000, other fitment in listing

That also listed a replacement part# 98767 which had a bunch of results when I put it into google.
Click to expand...
Yeah, that's what I need. I haven't called warn yet because it seemed like there were a few places that said they had it in stock but when I went to check out it was out of stock. The last place actually let me buy it and then sent me an email saying it was out of stock and asked if they wanted me to check with warn on a lead time. I didn't try to order from the link you posted because I thought the other place would have it.
 
Let me go look in the shed. I was given a parts winch several years ago, I think the drum is there.
 
Sorry got home and forgot, just ran out. No gearbox so no ID, looks like an M series winch. Roughly 8-1/4" wide drum, 8" diameter at the largest part of the drum. Look about right? I can drag it out tomorrow and separate off the drum.

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posford said:
Sorry got home and forgot, just ran out. No gearbox so no ID, looks like an M series winch. Roughly 8-1/4" wide drum, 8" diameter at the largest part of the drum. Look about right? I can drag it out tomorrow and separate off the drum.

KIMG0235_copy_4248x3186.jpg
Click to expand...
I didn’t have a chance to look at mine until tonight. My drum is 9” wide and 6” in diameter.
 
I have an M8000 drum under my workbench. I’ll dig it out this weekend and see what condition it’s in.
 
Thefishguy77 said:
Is it a direct swap?
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You will need a new drive gear. The old motors use a keyed shaft. The new motors use a splined shaft. The drive gear was around $35 a few years ago.

Might as well upgrade to the Albright contactor at the same time. Screw the solenoids that fail right when you need them.

If you do a search there are quite a few writeups that document the part number for the drive gear and the whole swap. It's not complicated.

Be warned. There is very little fine motor control. It's fast.

It pulls a lot of current also. You need a good charging system.
 
lt1yj said:
You will need a new drive gear. The old motors use a keyed shaft. The new motors use a splined shaft. The drive gear was around $35 a few years ago.

Might as well upgrade to the Albright contactor at the same time. Screw the solenoids that fail right when you need them.

If you do a search there are quite a few writeups that document the part number for the drive gear and the whole swap. It's not complicated.

Be warned. There is very little fine motor control. It's fast.

It pulls a lot of current also. You need a good charging system.
Click to expand...

bringing this back up from the dead. Which Albright contactors did you use to replace the solenoids?
 
m016324 said:
bringing this back up from the dead. Which Albright contactors did you use to replace the solenoids?
Click to expand...
I used the control from an M12000 winch.

I found a true Albright contactor on Amazon that I used on a buddies winch. I’ll post a link when I get home in a couple of days
 
I concur. $150 8274 xp motor and Albright solenoid. It surprises the shit out of people how fast it is. Mine had the new splined gear.
 
well, I guess I’ll add my Craigslist Warn purchase. Little did I know my ShittyBuilt would disappoint me slightly so this would be a new project for an upgrade.

I tried powering it in and out. Doesn’t move. Definitely melted some thin 14 gauge wire though. I tried jumping it a few ways, and quit when I realized I needed to buy/build a controller so no point fooling around with it anymore.

The motor might be burned out, or stuck.

$300 for the winch with no controller and the cradle. Amazon/Warn shows these for MUCH more today.
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I think this might have helped the motor stay put. It’s so sticky and tacky in the gears I’m scraping it off with a putty knife and flaking it off with a pick.
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