PAGE 16
8) Withdraw freespool extender item 262, and freespool coupling item 260, from inside of cable drum item 500.
9) Remove and inspect two thrust washers item 285, and thrust bearing item 287. Replace if cracked or
otherwise damaged.
10) To separate cable drum from final housing, first remove circlip item 513. Insert two heel bars between flange
of cable drum and final drive housing and gently pry cable drum out of ball bearing item 103.
11) Remove circlip item 109, and press ball bearing item 103, out of final housing item 100. Check ball bearing
and replace if damaged.
12) 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:
Reassemble final drive end of winch as follows
1) Press 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) With winch sitting flat on cable drum flange, install thrust bearing item 281, sandwiched between two thrust
washers item 279, into bore of cable drum item 500.
5) Install freespool spring item 280, and freespool sungear item 340, into cable drum bore.
6) 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 final planet
hub item 300. Retain with circlip item 313.
7) Insert final planet hub assembly into final housing item 100. Ensure that planet hub spline is fully engaged
with cable drum item 500.
8) Install thrust bearing item 263, sandwiched between two thrust washers item 261, onto end of freespool
sungear item 340.
9) Install new, well-greased O-ring item 265, into bore of end cover, item 120. Insert freespool piston item 264,
into cavity. Install new, well-greased O-ring item 123, into flange of end cover and verify that planet hub
stopper item 126, is installed onto end cover.
10) Carefully insert end cover item 120, with freespool piston item 264, into final housing item 100, and fasten
with retaining ring item 124.
11) 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) Install thrust bearing item 281, sandwiched between two thrust washers item 279, into cable drum item 500.
2) Install freespool coupling, item 260, into cable drum. Engage with splines of freespool sungear item 340, so
that end of freespool coupling goes through thrust washers item 279.
3) Install freespool extender item 262, into end of freespool coupling item 260, engaging end of freespool
sungear item 340, with freespool bushing item 270.
SERVICE INSTRUCTIONS
CONTINUED
256 REV.030718
