Usage:
Disassembly
Drain oil from winch as described in the "Preventative Maintenance" section of this manual.
Remove the six capscrews then remove the left-hand clutch shaft bearing carrier. Retain the shim set for reassembly.
Remove the first reduction drum drive gear, second reduction gear and pinion, freespool shift rail and yoke, if equipped with freespool. Refer to "Idler Shaft Group" section of this manual for additional information.
Install a long, 1/2 in. NC, capscrew into the end of the countershaft pin (6) to serve as a handle. Support the cluster gear (3) and remove the countershaft pin.
Thoroughly clean all parts and inspect for damage and wear. The bearing rollers should not exhibit and irregularities. If the rollers show any sign of spalling, corrosion, discoloration, material displacement or abnormal wear, the bearing should be replaced. Likewise, the cage should be inspected for unusual wear of deformation, particularly the cage bars. If there is any damage that will impair the cages ability to separate, retain and guide the rollers properly, the bearing should be replaced. The thrust washer contact areas should be free from any surface irregularities that may cause abrasions or friction. The gears and shaft should be inspected for abnormal wear or pitting. Replace if necessary.
Assembly
Lubricate and install new o-ring (4) into the groove on the countershaft pin (6). Lubricate and install two roller bearings (1) separated by a spacer (5) into the bore of the cluster gear (3).
Position the cluster gear (3) and outer thrust washer (2 or 7) in the winch case and at the same time, insert countershaft pin (6) through the bore into the thrust washer and cluster gear.
Position the inner thrust washer (2) in the winch case between the cluster gear and the inner case wall then fully install the countershaft pin.
Rotate the countershaft pin so that the slotted end is properly positioned to permit clutch shaft bearing carrier installation.
Install the first and second reduction gears and freespool linkage, if equipped. Refer to the "Idler Shaft Group" section for additional information. Install the shim set onto the clutch shaft bearing carrier and install the bearing carrier into the winch case. Tighten the capscrews to 75 lb-ft (102 N·m). torque.
NOTE: Be careful to properly align the clutch pressure port in the winch case, shims and bearing carrier.
Refill winch to the proper level with recommended oil.