Stock Warn Winch XD9000i Attempted Rebuild - Defender Source
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  #1  
Old September 14th, 2009, 09:13 PM
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Stock Warn Winch XD9000i Attempted Rebuild

I got this old winch as a freebie - its obviously in pretty bad shape but I figured it would be fun to try and bring it back to life.

The motor retaining bolts snapped off immediately after I put a wrench to them, and that was only a preliminary sign of the mess awaiting me when I got the motor off of the drum support.

The armature was stuck to the shaft (its supposed to come out with the motor), all the brushes were frozen in position, and the housing was full of dirt and corrosion.

I did manage to get all the gear housing hex-bolts out without breaking any - which seemed like a small miracle. Despite being covered in solidified grease and smelling strongly of camphor, the gears seemed to be in good shape.

The solenoid pack seems to be pretty decent, hopefully no work will be required here. The drum support bushings barely seemed worn at all, so I'm pretty sure this winch was purely decorative in its first life.

The worst parts are the drum supports (the upright pieces). The passenger side one has corroded all the way through and will definitely need replacing, and they're about a hundred dollars each from Warn. I think I'll just replace them both. Even if I have to replace a few other parts, the overall cost shouldn't be too outrageous.

The big question right now is the motor. I don't want to buy a new Chinese motor, so I need to find a good place to send it for a rebuild. Any suggestions?
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  #2  
Old September 15th, 2009, 08:15 AM
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It looks like the PO used it as an anchor!
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  #3  
Old September 15th, 2009, 12:52 PM
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LOL...Its perrrrfectly serviceable!

Any automotive starter/alternator rebuild shop should be able to handle the motor work. I had one done here a few years ago, cost me about 75 bucks I think. Good luck!
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  #4  
Old September 15th, 2009, 02:08 PM
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Jim,

I have a Warn motor from an XD9000i that should be in good condition. If you want it, you can have it. I would just ask that you pay shipping. Probably flat rate USPS priority mail, around $13.

Greg
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  #5  
Old September 15th, 2009, 02:21 PM
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Hey cool - I see its not exactly the same model, but I'll see if I can cannibalize the various parts to make a runner that fits my housing.

I PM'd you my FedEx number.
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  #6  
Old September 15th, 2009, 04:16 PM
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There is nothing wrong with those side pieces.
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  #7  
Old September 15th, 2009, 04:42 PM
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Quote:
Originally Posted by evilfij
There is nothing wrong with those side pieces.
Ok then, just trade me for your XD9000i and we'll call it even.

Follow-up Post:

I'll even re-assemble it!
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  #8  
Old September 18th, 2009, 08:41 PM
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Seriously, I will ship you my two side pieces and you ship me the bad ones.
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Old September 18th, 2009, 09:12 PM
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I'll ship them to you, and you can see if you can use them!
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Old September 18th, 2009, 10:03 PM
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Quote:
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I'll ship them to you, and you can see if you can use them!

I am sure they are ron good.
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  #11  
Old November 5th, 2009, 09:40 PM
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Any updates?
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  #12  
Old November 5th, 2009, 10:04 PM
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No, got stalled on this one. I don't think the freebie motor is compatible (it doesn't directly mate up). I'm hoping I can re-used the guts, but I've been on such a mission to put the truck together that the winch has fallen by the wayside...
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  #13  
Old November 6th, 2009, 09:19 AM
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What's the concensus on the ebay and similar replacement motors? I have a 9000i in a 5 gallon bucket, all in parts. I think the only thing holding me back is the motor rebuild. And time. But I blame the motor.
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Old November 6th, 2009, 11:13 AM
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Thumbs up

I bought one of the ebay rebuilds from DB Electrical (800.753.2242) in 10/07. It was a higher hp rating than my original (big smile there). It's been two years with plenty of use and it has worked flawlessly with quite a bit more power (more windings ?) than the original. I would highly recomend them.

The part # was AMT0406-New Warn 20 spline Heavy Duty $99.95
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Old November 6th, 2009, 02:22 PM
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X2 on DB Electrical. Good people.
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  #16  
Old November 6th, 2009, 07:31 PM
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x3 and 4

got a motor for my xd9000i and a starter for my 109 (with 3.0 GM engine)

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X2 on DB Electrical. Good people.
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  #17  
Old December 17th, 2010, 08:01 PM
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I know it's been a while, but did anyone who bought a motor from DBelectric have any issues with them?
I bought one for my XD9000 (26626 motor) and it seem like the motor isn't an exact replacement.
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Old December 17th, 2010, 08:56 PM
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I did the "conversion" a few years ago. I remember the new motor being a little longer, but all in all pretty much the same.
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Old December 17th, 2010, 09:19 PM
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Quote:
Originally Posted by MaineZuke View Post
I know it's been a while, but did anyone who bought a motor from DBelectric have any issues with them?
I bought one for my XD9000 (26626 motor) and it seem like the motor isn't an exact replacement.
Still better than the original.
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  #20  
Old December 18th, 2010, 08:39 AM
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It is a nice quality feeling motor.
The problem I found is when I mounted the armature to the sideplate, the brushes didn't make full contact with the commutator. They were about 3/16" off the end of it. Wrote to DBelectric and they said to shim the bearing which would leave mean less contact of the splines with the "drive cup"

I can't find many people who have used this motor on this winch, so I was just looking for other experiences with them
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