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5) If it is necessary to remove primary planet gears, remove circlip, item 411, and press planet pin, item 410, out of
planet hub, item 400. Inspect needle bearing, item 423, and two thrust washers, item 421, and replace if damaged.
6) Inspect internal gear stopper, item 412, for excessive wear. Replace if less than .10 inch protrudes out the
end of planet pin, item 410.
7) Remove sungear stopper, item 444, from primary planet hub and replace if less than .19 inch thick.
8) To separate cable drum from final housing, first remove circlip, item 513. Insert two heel bars between the
flange of the cable drum and the final drive housing and gently pry cable drum out of ball bearing, item 103.
9) Remove circlip, item 109, and press ball bearing, item 103, out of final housing, item 100. Check ball bearing
and replace if damaged.
10) Remove and discard oil seal, item 105.
REASSEMBLY
Thoroughly clean all parts. Use only new, well-greased O-rings and oil seals. Unless otherwise specified, torque
fasteners per BOLT TORQUE CHART at back of manual.
REASSEMBLY OF FINAL DRIVE:
Reassembly final drive end of winch as follows:
1) Press a new, well-greased oil seal, item 105, into final housing, item 100.
2) Press ball bearing, item 103, into final housing and secure with circlip, item 109.
3) Press cable drum, item 500, into ball bearing, item 103, and secure with circlip, item 513.
4) Reassemble final planet hub assembly. Press needle bearing, item 323, into final planet gear, item 320.
Position thrust washers, item 321, on either side of planet gear and press planet pin, item 310, into the final
planet hub, item 300. Retain with circlip, item 311.
5) Insert final planet hub assembly into final housing, item 100. Ensure that planet hub spline is fully engaged
with cable drum, item 500.
6) Verify circlip, item 343, is installed on splined end of final sungear, item 340. Insert final sungear through center
of three final planet gears, item 320, and into cable drum. Engage gear end with the three final planet gears.
Winches with optional 'B' reduction ratio only:
6A) Insert planet hub stopper, item 128, into planet hub, item 300.
7) Install a new, well-greased O-ring, item 123, into end cover, item 120. Verify that planet hub stopper, item 126,
and sungear stopper, item 122, are installed into end cover.
8) Gently insert end cover into final housing, item 100, and fasten with retaining ring, item 124.
9) Temporarily remove breather relief valve, item 130, from end cover. Turn winch up on end with cable drum opening upwards.
REASSEMBLY OF PRIMARY DRIVE:
Reassemble primary drive as follows:
1) Reassemble primary planet hub assembly. Press sungear stopper, item 444, into primary planet hub, item 400.
Press needle bearing, item 423, into primary planet gear, item 420. Position thrust washers, item 421, on either side
of planet gear and press planet pin, item 410, into the primary planet hub, item 400. Retain with circlip, item 411.
2) Install primary planet hub onto end of final sungear, item 340, inside of cable drum, item 500.
3) Install internal gear, item 430, over top of three primary planet gears, item 420. Ensure gear teeth are fully
248 REV.960101
SERVICE INSTRUCTIONS
CONTINUED
