Usage:
The idler shaft group and freespool components, which include the first reduction gear, second reduction pinion and freespool linkage, are located on the left hand side of the winch, when viewed from the rear.
Removal of these components for repair may be accomplished with the winch mounted to the tractor.
Removal
Drain oil from winch as described in the "Preventative Maintenance" section of this manual.
Remove the two capscrews (5) and lock plate (4) from the idler shaft bearing carrier (14) and adjuster assembly.
Remove the four capscrews (6, 7) securing the idler shaft bearing carrier (14) and adjuster to the winch. Use two (2) capscrews as jackscrews, and remove the carrier and adjuster assembly.
Note the location of the two long capscrews for reassembly.
Inspect the bearing cup and replace as required.
Turn the adjuster (10) counter-clockwise and remove it from the bearing carrier. Remove and discard the o-ring (3) from the carrier.
Remove the capscrews from the large diameter second reduction shaft bearing carrier cover and carefully remove the cover.
With a lifting fixture or sling, remove the second reduction drum drive gear and shaft assembly from the winch case. Gear and shaft assembly weight is approximately 125 lb (56 kg).
Freespool Units Only
Remove the shaft rail lock plug (8) from the winch case.
Turn the freespool shift rail (21) counter-clockwise until the threads are free of the winch case. Remove the freespool shift rail and freespool shift collar and yoke assembly (22).
Inspect the freespool shift yoke (22) from excessive wear and replace as required.
Insert the freespool shift rail into the collar and determine the detent positions on the rail. Replace ball plunger (17) (later units use two) in the collar if the detent appears weak.
All Units
Move the first reduction gear and pinion assembly (12, 13) outward to unseat the inner bearing cone from the bearing cup in the winch case wall.
Carefully move the gear and pinion assembly into the drum drive gear opening and remove from winch case.
Inspect the bearing cup in the winch case wall and replace as required.
Support the first reduction gear (13) in the suitable hydraulic press and press the second reduction pinion (12) free of the inner bearing cone.
Support the second reduction pinion and remove the outer bearing cone.
Inspect the bearing cone (1) and thrust washer (9) for wear or damage and replace as required.
Freespool Units Only
Inspect the floating bushing (11). The bushing should slip freely over the second reduction pinion.
Operate the remaining freespool linkage within the winch case. Inspect for wear and damage.
If the control cable must be replaced, unscrew the freespool cable core from the freespool cable connector (25).
Loosen jam nut (23) and turn threaded cable and adjuster (32) counter-cockwise until the control cable and adjuster may be removed from the winch case.
Remove the inner retaining ring (20) from the control cable and remove the threaded cable adjuster. Remove the outer retaining ring and o-ring (31) from the control cable.
Assembly
Freespool Linkage Installation
If the freespool shift linkage was removed from the winch case, install the linkage as follows.
Install jam nuts (18) on rod ends (19) until nuts bottom on the threads by the rod eye. Install the upper rod end in the winch case, until the jam nut is nearly in contact with the inner case wall and the pin bore is vertical. Tighten the jam nut.
Install the lower rod end in the winch case to approximately the same distance as the upper rod and tighten the jam nut.
Position bell crank (26) between the rod ends and insert pin (30) through the rod ends with the drilled end at the top. Install cotter pin (16).
Position end of cable connector (25) through the bell crank arm. Secure in place with washer (28) and cotter pin (16).
Work the freespool linkage in the winch case back and forth to make sure that binding does not occur.
Lubricate and install o-ring (31) into the groove on the control cable.
Install threaded cable adjuster (32) and jam nut (23) onto the control cable over the o-ring. Install two retaining rings (20) to secure threaded adjuster in position.
Install the control cable in the winch case and turn the threaded adjuster into the winch case until the outer end of the adjuster is approximately 1 1/2 in. (38 mm) from the machined surface of the winch case. Rotate the outer end of the control cable core clockwise and thread the cable core into the cable connector (25).
Operate the control cable at the outer end and check the freespool shift linkage for smooth operation.
Attach shift yoke (22) to shifty collar (24) with two 3/8 inch x 3/4 UNC capscrews (27) and tighten to 31 lb-ft (42 N·m) torque.
Coat the threads of the shoulder screw (15) with Loc-tite 242 or equivalent and install in the shift collar. Tighten shoulder screw to 18 lb-ft (24 N·m) torque.
Install ball plunger(s) (17) into the shift collar.
Insert shift rail (21) into shift collar and align a detent groove with the ball plunger. (Later models use two ball plungers.)
Tighten the ball plunger until the shift rail will not rotate. Back-out the ball plunger 1/8 turn or until the shift rail can be rotated by hand. Check for positive ball plunger detent in both grooves on the shift rail. Remove the shift rail from the collar.
All Units
Place the second reduction pinion (12) on a flat surface with the stepped end facing up.
Lubricate the bushing (11) and mating surface of the second reduction pinion with winch lubricant and install the bushing over the pinion. Later, non-freespool winches do not contain the bushing.
If equipped with freespool, install the freespool clutch collar (29) over the first reduction gear with the beveled side of the collar facing down toward the large end of the pinion.
If not equipped with freespool, install the splined collar over the first reduction gear. Secure the collar in place with a 1/4 x 1 1/4 in. roll pin. The roll pin will protrude 1/2 in. (13 mm) from the outer diameter of the collar and be driven into the groove behind the gear teeth of the first reduction gear.
Lubricate the outside diameter of the bushing and the bore of the first reduction gear bore with winch lubricant. Install the first reduction gear and collar over the bushing, aligning the second reduction pinion (12) teeth with the splined collar teeth.
Later, non-freespool winches do not contain the bushing.
Install the thrust washer (9) over the second reduction pinion and into the recess of the first reduction gear.
Install the inner bearing cone over the end of the second reduction pinion. Press the bearing cone until firmly seated against the thrust washer (9).
Install the outer bearing cone over the second reduction pinion. Press the bearing cone until firmly seated against the pinion shoulder.
Lubricate and install the bearing cup into the inner wall of the winch case.
Place the first reduction gear and second reduction pinion assembly into the winch case opening, aligning the inner bearing cone within the bearing cup.
Freespool Units Only
Install the shift yoke and collar assembly in the winch case, placing the shift yoke in the groove of the freespool clutch collar (29) and shift collar shoulder screw in the slot of the freespool shift linkage. At the same time, insert shift rail (21) through the outer case wall and into the shift collar. Turn the shift rail clockwise until the end of the shift rail is approximately 1 inch (25 mm) into the winch case.
Position the shift collar on the shift rail so that the ball plunger is engaged in the detent groove at the inner end of the shaft rail. Rotate the shift rail until the clutch collar just clears the end of the teeth on the second reduction pinion.
NOTE: Final freespool shift adjustment is to be made after the assembly of the remaining components.
All Units
Make certain that the lube tube is aimed toward the second reduction pinion gear before installing the second reduction gear and drum drive shaft assembly. Make certain that the tube will not rub against any gears.
Lubricate the splines of the second reduction gear shaft with general-purpose grease and install the second reduction drum drive gear and shaft assembly into the winch case. Firmly seat the shaft against the retaining ring in the cable drum bore.
Apply silicon sealant 730 RTV or equivalent, to the sealing surface of the large diameter second reduction gearbearing carrier cover and install it onto the winch case. Apply thread sealant to the capscrews and install them finger tight. DO NOT tighten the capscrews at this time.
Lubricate and install o-ring (3) into the groove in the bearing carrier (14). Install threaded adjuster (10) into the bearing carrier until the adjuster passes through the o-ring.
Install the bearing cup into the bearing carrier until it is seated against the threaded adjuster.
Apply silicon sealant 730 RTV or equivalent to the mounting surface of the bearing carrier.
Install the bearing carrier assembly to the winch case. Apply thread sealant to the capscrews and tighten to 75 lb-ft (102 N·m) torque. Tighten the capscrews around the large bearing carrier cover to 75 lb-ft (102 N·m) torque.
Using a long screwdriver or pry bar, turn the threaded adjuster clockwise until tight. Tap the adjuster with a hammer to seat the bearing and continue turning until the adjuster can no longer be tightened. Back the adjuster out no more than 1/16 turn maximum and secure with lock plate and capscrews. Tighten capscrews to 75 lb-ft (102 N·m) torque.
NOTE: Tightening the threaded adjuster pushes the tapered bearing cup (outer race) into closer contact with the bearing cone and increases the bearing drag; much like tightening a wheel bearing nut on an automobile or truck. The snug fitting bearing cup will NOT move outward with the threaded adjuster when the adjuster is loosened. The winch must be operated under load for a brief period to allow the gear train load to push the outer bearing cup out against the threaded adjuster before a reduction in bearing drag can be noticed.
Recheck the adjustment of the freespool shaft rail by shifting the freespool cable into and out of engagement. Rotate the drum by hand to align gear teeth. The shift collar must clear the end of the second reduction pinion gear teeth when placed in the "disengaged" position.
Lock the shift rail in position with threaded plug (8). Apply Loc-tite 242 or equivalent to the threads of lock plug (8).
Refill winch to the proper level with recommended oil.