Disassembly
Remove the right hand winch housing cover.
Remove the two long capscrews securing the control valve to the mounting plate. Remove the spin-on filter and lower the control valve in the winch case.
Remove the two capscrews and lock plate from the idler shaft bearing carrier and adjuster assembly.
Remove the four capscrews securing the idler shaft bearing carrier and adjuster to the winch. Use two capscrews as jackscrews to remove the carrier from the winch.
Remove the capscrews (5) from the large diameter bearing carrier cover (14) and remove the cover.
Remove the second reduction drum drive gear and shaft assembly (12, 13) from the winch.
Remove the freespool cylinder yoke assembly from the first reduction gear.
Move the first reduction gear and pinion assembly outward to unseat the bearing cone from the bearing cup in the case wall. Carefully move the gear and pinion assembly into the drum drive gear opening and remove them from the winch case.
Support the cable drum with a nylon sling and remove capscrews (4) from the right hand drum bearing carrier (15). Using jackscrews, remove the drum bearing carrier.
Remove capscrews (4) from the left hand drum bearing carrier (15) and lube tube clamps. Using jackscrews, remove the drum bearing carrier.
NOTE: Split shims (16) are located between bearing carriers (15) and the winch case. Retain the shims in their original location reassembly.
Inspect bearing cones (3) and replace as required.
Remove and discard O-rings (6) from the drum bearing carriers.
Remove cable drum oil seals (9).
Inspect bearing cups (2) and replace as required.
Check the condition of snap ring (8) in the splined bore of cable drum and replace as required.
Assembly
Install bearing cups (2) into cable drum (11). With a .002 in. (.05 mm) feeler gauge, make certain cups are fully seated against the shoulder in the cable drum bore.
Install oil seals (9) into the cable drum with the spring side of the seal facing toward cable drum.
If it was removed earlier, install snap ring (8) into the groove in the splined bore of cable drum with sharp edge of the snap ring toward the center of the drum.
Lubricate and install O-rings (6) onto the cable drum bearing carriers.
Lightly lubricate bearing cones (3) with multi-purpose bearing grease and install onto the bearing carriers.
Suspend the cable drum in the winch case with the cable ferrule pocket on the right hand side. Lubricate the bearing cups (2) and oil seals (9) with general purpose grease. Install the right hand bearing carrier into the winch case and cable drum using the original shim set (16), if available. Apply non-hardening thread sealant to the capscrews and tighten to 75 lb-ft (102 N·m) torque.
Install the left hand drum bearing carrier (15) with the original shim set, if available. Secure the lubrication tube and oil line into proper position with clamps. Apply non-hardening thread sealant to capscrews and tighten to 75 lb-ft (102 N·m) torque.
Attach a dial indicator to the left hand bearing carrier and position the indicator stem against the retaining ring (8) in the cable drum bore. With a large screwdriver, pry drum from side to side to check for end play of .005-010 in. (.13-.25 mm). Add or remove shims (16) as required, while keeping the cable drum centered in the winch case.
NOTE: It is best to keep the drum end play close to the minimum valve given above.
Install the first reduction gear and pinion assembly into the winch. Install the freespool cylinder and yoke. Refer to the "Idler Shaft Group" section of this manual for additional information.
If the second reduction gear and shaft had been disassembled, install the second reduction gear (12) onto shaft (13) and secure in place with two retaining rings (7). Lightly pack bearing (1) with general purpose bearing grease and press onto shaft (13).
Install second reduction gear and shaft assembly into the winch while meshing the gear teeth with the pinion and the shaft splines with the drum.
Clean the mating surface of the winch case and bearing carrier cover (14). Apply silicone sealant 730 RTV or equivalent to the winch case.
Install the bearing carrier cover into the winch. Apply non-hardening thread sealant to the capscrews (5) and install finger tight.
Apply silastic sealant to the cleaned surfaces of the idler shaft bearing carrier. Install the idler shaft bearing carrier and tighten the capscrews to 75 lb-ft (102 N·m) torque. Evenly tighten all remaining cover capscrews to 75 lb-ft (102 N·m) torque.
Adjust the idler shaft bearing adjuster per instructions found in "Idler Shaft Group" section of this manual. Install adjuster lock plate and tighten capscrews to 75 lb-ft (102 N·m) torque.
Place the control valve into position and install capscrew and tighten to 75 lb-ft (102 N·m) torque.
Install the winch housing cover with a new gasket as required. Apply non-hardening thread sealant to the capscrews and tighten to 75 lb-ft (102 N·m) torque.
Refill winch with recommended lubricant.