The idler shaft group and freespool components, which include the first reduction gear, second reduction pinion and freespool linkage, are located on the LH side of the winch, when viewed from the rear.
Removal
Drain the oil from the winch as described in the :Preventative Maintenance" section of this manual.
Remove two capscrews (7) and the lock plate (13) from the idler shaft bearing carrier (12) and adjuster assembly.
Remove the four capscrews securing the idler shaft bearing carrier and adjuster assembly to the winch. Use two (2) of these capscrews as jackscrews, and remove the carrier and adjuster assembly, (Use 1/2-13 tap to clean paint from jackscrew holes.)
Note the location of the two long capscrews.
Inspect the bearing cup and cone. Replace as required.
Turn the adjuster (6) counter-clockwise (CCW) and remove it from the bearing carrier. Remove and discard the O-ring (14) from the carrier.
Remove the capscrews from the large diameter second reduction shaft bearing carrier cover, and carefully remove the cover. There are two jackscrew holes in the cover.
With a suitable lifting fixture or sling, remove the second reduction drum drive gear and shaft assembly from the winch case. The gear and shaft assembly weight is approximately 155 lb (70 kg).
Remove the freespool hose from the cylinder.
Remove the cylinder rod capscrew (20), spring (18) and retainer washer (19) from the winch case.
Rotate the cylinder assembly (15) around the clutch collar (11) toward the case wall opening and remove it from the winch case.
You may remove the cylinder stud (17) from the winch case, as required.
Together, remove the second reduction pinion (9) and first reduction gear (10) from the winch case. Press the pinion from the gear and bearings.
Inspect the bushing (8) in the first reduction gear for scoring or excessive wear. The bushing should fit freely over the pinion.
Inspect the bearing cup in the inner case wall and replace as required.
Freespool Cylinder Assembly Service
Remove the capscrew (20), retainer washer (27), springs (23) and spring guides (26).
Remove the cylinder rod (20) from the cylinder (21).
Inspect the sealing surfaces for scoring or other abnormal wear and replace components as required. Use new O-rings (24, 24) when reassembling.
Apply Loctite 242, or equivalent, to clean, dry threads of the capscrews during reassembly.
Assembly
Place the second reduction pinion on a flat surface with the small diameter end facing upward.
Lubricate the bushing and mating surfaces of the second reduction pinion with new winch oil, and install the bushing over the pinion.
Install the freespool clutch collar over the first reduction gear with the beveled side of the collar facing down toward the large end of the pinion.
Lubricate the outside diameter of the bushing and the first reduction gear bore with new winch oil. Install the first reduction gear and clutch collar assembly over the bushing, aligning the second reduction pinion teeth with the splined collar teeth. The clutch collar MUST be installed with the chamfered edge toward the pinion.
Install the thrust washer (5) over the second reduction pinion and into the recess of the first reduction gear.
Press the inner bearing cone over the end of the second reduction pinion, until the bearing cone is resting firmly against the thrust washer.
Press the outer bearing cone over the end of the second reduction pinion, until the bearing cone is resting firmly against the pinion shoulder.
If required, lubricate and install the bearing cup into bore in the inner wall of the winch case.
Place the first reduction gear and second reduction pinion assembly into the winch case opening, aligning the inner bearing cone within the bearing cup.
If required, install the cylinder stud into the winch case. Use Loctite 242, or equivalent, on clean, dry threads.
Install the freespool cylinder assembly into the winch case. Engage the collar with the yoke. Rotate the cylinder assembly into alignment with the cylinder stud. BE SURE the roll pin in the stud engages the hole in the cylinder assembly.
Install the capscrew, spring, and retainer. Apply Loctite 242, or equivalent, and torque to 45 lb-ft (61 N·m).
Temporarily install the idler shaft bearing carrier subassembly (bearing carrier, adjuster and O-ring) into the winch case to support the outer end of the second reduction pinion. Apply shop air pressure, approximately 100 PSI (69 kPa), to the freespool cylinder. Adjust the freespool cylinder stud into the winch case wall as required to allow the clutch collar to clear the edge of the pinion teeth, but still maintain maximum tooth contact while engaged. Install the hydraulic hose onto the freespool cylinder.
Make certain the lube tube is aimed toward the second reduction pinion gear before installing the second reduction gear and drum drive shaft assembly. Be sure the tube will not rub against any gears.
Lubricate the splines of the second reduction gear shaft with general-purpose grease and install the second reduction drum drive gear and shaft assembly into the winch case. Firmly seat the shaft against the retaining ring in the cable drum bore.
Apply silicon sealant, RTV 730 or equivalent, to the sealing surface of the large diameter second reduction gear bearing carrier cover and install it onto the winch case. Apply thread sealant to the capscrews and install them finger tight. DO NOT tighten the capscrews at this time.
Lubricate and install the O-ring (14) into the groove in the bearing carrier. Install the threaded adjuster (16) into the bearing carrier until it is lightly seated against the bearing.
Apply silicon sealant, RTV 730 or equivalent, to the mounting surface of the bearing carrier.
Install the bearing carrier to the winch case. Apply thread sealant to the capscrews and torque evenly to 75 lb-ft (102 N·m). Evenly tighten the large cover capscrews in a cross pattern to 75 lb-ft (102 N·m) torque.
Using a pry bar or a screwdriver approximately 18 in. (460 mm) in length, turn the threaded adjuster clockwise (CW) until tight. Tap the adjuster with a hammer to seat the bearing and continue turning the adjuster, then tapping with the hammer, until it can no longer be tightened. Back the adjuster out, by turning counter-clockwise (CCW), 1/16 turn maximum (22.5°) and secure in place with the lockplate and capscrews. Torque the lock plate capscrews to 75 lb-ft (102 N·m).
NOTE: Tightening the threaded adjuster pushes the bearing cup (outer race) into heavier contact with the bearing cone, increasing the bearing drag; much like tightening a wheel bearing nut in an automobile or truck. The snug fitting bearing cup will not move outward with the threaded adjuster when the adjuster is loosened. The winch MUST be operated under load for a brief period to allow the gear train load to push the bearing cup outward against the adjuster before a reduction in bearing drag is noticed.
