8274 rebuild - Defender Source
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  #1  
Old February 18th, 2012, 07:38 PM
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Tony Brooks
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8274 rebuild

I thought I might post up my experience so far rebuilding an 8274.

By way of background, I had been looking for a winch for the 90 for a while. Craigslist delivered in the form of an 8274 that had been removed from an fj40 years ago and left outside since. It worked, but was ugly, obviously needed a new line and electrics and to be removed from the 5 tons of steel winch mount that the mounting bolts were welded to. The good news is that it was cheap, local, and rebuildable. And an 8274.

I brought it home and realized that the bolts had fused to both the nuts and the body of the winch itself, necessitating a new lower housing and end cap, both of which Ed Angel hooked me up with (thanks again!). Having read the various rebuild threads on the web, I dove in this morning.

First step was to pull the solenoid pack as the wires from the solenoids to the motor were rotten. I'll likely just make up new ones as warn only appears to sell the entire pack. There was no need to pull the clutch or motor as the three retaining bolts were readily accessible. From there, a little pulling and the top assembly came free.

I then put the new lower housing and end cap through the parts washer and primed and painted them since they were there and I found half a can of rustoleum on a shelf. At this poi t the head scratching began. Most of the information I found online implied that the brake needs to be disassembled before the main shaft will come out. Again, I have to install everything in the new lower housing, otherwise I would have left it alone as the gears and seals all looked 100%. However, I'm now at a (predicted) point where neither the brake assembly is coming off the shaft and the main shaft isnt budging from the housing. I have a tensioned puller on the brake and. The who,e thing is covered in PBBlaster, so with any luck something will give up soon.

Anyway, these things appear to be really relatively simple to rebuild, and with any luck this will be installed sooner the truck. In the mean time, if anyone has thoughts on the brake/mains haft issue. . .

Pictures coming soon.
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  #2  
Old February 18th, 2012, 07:46 PM
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William Skidmore
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I have a list of webpage links and websites with info for the 8274 on my personal computer which I will put up. (if you dont mind) There is an extensive thread on the pirate4x4 from way back and I think something on here too.
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  #3  
Old February 18th, 2012, 07:50 PM
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John B.
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The brake shaft should come out fine with the brake on it. You lift the retaining plate and tap the whole thing off. http://www.red90.ca/rovers/8274_brake/8274_brake.html

You should overhaul the brake regardless. They always rust solid when left outside. They can be very seriously rusted to the shaft....
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  #4  
Old February 18th, 2012, 08:05 PM
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That billavista write up was great.

John, thanks for the link. I did tap on the Main shaft a bit (yes with the plate up)but didn't feel much success before I ran out of time to work. I may try that again tomorrow.
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  #5  
Old February 18th, 2012, 08:53 PM
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Framing hammer and brass drift got the shaft halfway out. Looks like I'll need a new bearing for the new housing. Which warn gets $25 for! There must be an alternate part number out there somewhere.
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  #6  
Old February 18th, 2012, 10:09 PM
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Tony

I have a bunch of small parts as well if you need any of the brake parts etc.

Ed
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  #7  
Old February 18th, 2012, 10:12 PM
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Thanks Ed. Let me get therest of it disassembled and see where I wind up.
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  #8  
Old February 19th, 2012, 10:45 AM
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Definitely take the brake apart and at a minimum make sure it's ok. This is likely to be the worst off than any other part of the winch though.

Mine is still in pieces. Hopefully you working on yours will motivate me, but it's unlikely

Search for other parts vendors. I forget where I got my parts from but they were cheaper than directly from warn.

But please do show pictures.
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  #9  
Old February 19th, 2012, 11:02 AM
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Here are a few pictures, the lower case painted with the brake pawl installed, refinished end plate, the scrotty solenoid wiring (wonder where I can source those wires and connections anyway?) and the extent to which I've gotten the main shaft out so far.
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  #10  
Old February 19th, 2012, 03:35 PM
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Skip the warn solenoid setup and get an Albright solenoid from EE. I did this with my 8274 and it the easiest route and the albrights get great reviews.
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  #11  
Old February 19th, 2012, 03:45 PM
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It appears summit racing has everything in stock, including the allbright solenoid with very good pricing.
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  #12  
Old February 20th, 2012, 07:38 AM
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The 2nd page chronicles my 8274 rebuild. http://forum.roversclub.org/forum/sh...ight=belleview

The 8274 is amazing. It is simple to fix and repair and is still made because the design wasn't broken. IMO it looks perfect on a Defender/Series truck over just about any winch.
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  #13  
Old February 20th, 2012, 10:14 AM
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When I rebuilt my M8000 I bought my parts from two sources:

Amazon.com
4wheelparts.com

With my Prime free shipping, the amazon stuff was cheaper than used parts.

4wheelparts ALWAYS runs %off and free shipping deals...source stuff here that was cheaper than amazon.

Bought two endplates, seals, and the tie rods for almost nothing...
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  #14  
Old February 20th, 2012, 11:50 AM
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So the only place that had everything in stock was Warnserviceparts.com. Everything should be here by the weekend which will give ample time to continue soaking the main shaft in PB blaster.
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Old February 20th, 2012, 10:59 PM
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Warn 8274 rebuild pirate4x4
Bellview Tech, the 8274's daddy - Alaska 4x4 Network
OLD Warn Winches -
Warn 5687 Information
Replacement Winch Motors
12voltguy.com - Home
Warn 8274 custom mods? - Pirate4x4.Com Bulletin Board
Warn 8274 Electrical Tech
Champion 6.5hp Motor Upgrade for Warn 8274 Winch : Devon 4x4
BC4x4.COM
Warn 8274 2 motor adaptor - LR4x4
Piedmont South Carolina parts for winch
Blackjacks 8.7AK - Pirate4x4.Com Bulletin Board
Flamin Fabrications - Twin winch adapter, Winch modification

Sorry it took so long to get up.
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Just to be clear, i was not bragging. i was calling you a pussy. Ren Ching
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  #16  
Old February 21st, 2012, 02:03 AM
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Quote:
Originally Posted by Abrooks View Post
So the only place that had everything in stock was Warnserviceparts.com. Everything should be here by the weekend which will give ample time to continue soaking the main shaft in PB blaster.
That site also has all of the service manuals....however I found I could save 1/2 by sourcing for 2-3 different places.
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  #17  
Old February 26th, 2012, 10:27 PM
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Neither the brake assembly nor the main shaft wants to move. I've gotten the main shaft approximately 3/4" out, but it feels as though it's hitting something -- maybe the inside flange of the bushing? The brake assembly will move approximately 1/4" on the main shaft, but without the puller actually tensioned on the brake, it will reseat itself. Shift of taking this to a machine shop I'm at a loss for what to do next. The constant application of a variety of snake oil penetrating fluids makes me feel a though I'm doing something, but you'd think that -0 days of near constant kroil and pb blaster, pullers and prying would do something.

Any ideas?
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  #18  
Old February 26th, 2012, 10:47 PM
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John B.
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Heat.

Is the brass bushing coming out of the housing or the shaft moving in the bushing?
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  #19  
Old February 26th, 2012, 11:06 PM
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Both. Heat didn't appear to make any difference. . .
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  #20  
Old February 29th, 2012, 02:39 PM
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Quote:
Originally Posted by galen216 View Post
The 8274 is amazing. It is simple to fix and repair and is still made because the design wasn't broken. IMO it looks perfect on a Defender/Series truck over just about any winch.
Uh.
Mine was a bargain, with only two events done and at a reasonable price.
Along the way I swapped the motor with the XP 6hp (I doubt there are 6hp in there tho),
fitted Albrights, twin batteries.

It looks cool no doubt, I appreciate the extra wire compared to the average winch, and the external brake.
But it's far from being amazing.
Even with uprated alternator and the XP it gets warm/hot after a long pull, and the whole thing has so much play from the factory which frankly seems scary to me, I don't care if the project is old, the design leaves a lot to desire.
Some challenge guys here put spacers to get rid of the play, and aftermarket freespools because in stock form is a royal PITA.

The most annoying thing recently is the KA-RANK noise it makes every now and then, I noticed while spooling the cable in, manually...so no load on the cable!
A mate has an 8274 on his YJ, and makes the same noise.
Checked many time, all internals are just fine, no apparent reason.
Gremilins.

I like mine and I'll keep it, it works ok and never let me down, but the more I look at it the more it looks like an expensive electrical toy.

If I'll have the chance I'll go PTO/mechanical/hydro on the 109".

Just my thoughts.
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