WARN WINCH RE­BUILD

4WDrive - - Contents - Story and Pho­tos by Bryan Irons @Bryanirons

Our buddy Colin has been snoop­ing around for a good, used winch that won’t break the bank to sad­dle on his trail rig. While buy­ing a name-brand, used winch can save some money, you re­ally have to ques­tion why the seller is get­ting rid of it. Do they need the cash? Is there some­thing wrong with it? Is it stolen? It’s not of­ten the front of a 4x4 doesn’t need a winch any­more, es­pe­cially a good one, so when he had score a “smokin’ deal” on a 9000 lb Warn winch… we were a bit hes­i­tant to share his en­thu­si­asm.

We de­cided to take a look for our­selves. Our eyes were im­me­di­ately greeted with the fa­mil­iar red “W” on the front of what turned out to be a clas­sic, and still made, XD9000i. Although not as fa­mous as its older brothers the 8274 and the M8000, the XD9000i has the ad­van­tage of an in­te­grated so­le­noid pack, and a stan­dard 10” X 4.5” mount­ing pat­tern. The 9000 lb sin­gle line pulling strength is cour­tesy the 4.6hp se­ries wound mo­tor and can pack a whop­ping 125’ of ca­ble. Many recre­ational off-road ve­hi­cles pack an XD9000i, but we typ­i­cally see them strapped to the front of work trucks des­tined for the woods. Hy­dro, tele­com, rail and other out­fits have taken a lik­ing to the Warn, mak­ing them a bit eas­ier to get your hands on.

Our ini­tial gleam­ing re­ac­tion to Colin’s find was soon tem­pered by re­al­ity as we

ap­proached the work­bench. Cast alu­minum doesn’t like salt-cov­ered roads and this one was show­ing the stress with flak­ing pow­der coat­ing and miss­ing de­cals. The mo­tor end cover had a hole in it, and mount­ing feet were bro­ken off the cast side plates… 3 of 4 in to­tal. Add to this the miss­ing re­mote and the only words we could muster were “You lose a bet?” A fresh “Queen El­iz­a­beth II” was all it took to get the Warn in Colin’s pos­ses­sion, even for a parts winch that works, that isn’t too bad see­ing as re­tail is hov­er­ing around $1550 CAD.

Had this find been of a lesser name brand, we would have scoffed and told Colin to just burn the $20 the next time he finds a “deal” like this. Luck­ily for him, Warn of­fers re­place­ment parts and com­po­nents for just about every winch they have ever pro­duced. We used Warn’s on­line re­place­ment parts guide to dis­cern ex­actly what pieces we needed, as there have been a few vari­ants of the XD9000i winch. Warn au­tho­rized deal­ers have ac­cess to all the com­po­nents, as op­posed to or­der­ing di­rect from Warn, and you can find one close to you on Warn’s web­site. On­line sell­ers and eBay are an­other op­tion, but call­ing and chat­ting with a dealer seem to get us bet­ter prices and ser­vice.

Af­ter a thor­ough in­spec­tion, we knew what we needed for parts and pieces - two new ends plates, a new re­mote con­trol, and for added in­surance… a brand spankin’ new mo­tor. We prob­a­bly could have save $200 and reused the old mo­tor and pos­si­ble scrounged for a new end plate, or had the mo­tor gone through by a lo­cal elec­tric mo­tor rewinder, but a new unit seemed like the right choice. An­other op­tion was to omit the new re­mote and cob­ble some­thing to­gether, but this isn’t “4WDrive Hacks” and we have had a cheapy re­mote fail on the trail al­ways at the worst time.

The new parts were on our door step within a week to the tune of about $500 CAD. Af­ter a few hours in the shop we had what is es­sen­tially, a brand-new winch for a frac­tion of the price. This par­tic­u­lar unit was at the ex­treme end of what we would say is eco­nom­i­cally vi­able for a re­build and re­pair. We just can’t get be­hind the idea of spend­ing peanuts for a new over­seas made unit, given the build qual­ity and short life­span we have wit­nessed in the past. With a lit­tle el­bow grease, and about the same dol­lar fig­ure up front, you to can walk away with a win­ner. Fol­low along as we scrap the shrap­nel and end up with a re­li­able unit ready for a fu­ture of hard work.

Warn - www.warn.com/re­place­men­tParts/ Odyssey Bat­ter­ies www.odyssey­bat­tery.com Ni­tro Lube - www.ni­trol­ube.com Pro­Long - www.pro­long.com

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