Apply light pressure to the thrust ring and remove the retaining ring. Then remove the thrust ring, brake plates, friction discs and wave springs from the carrier.
Remove the planet gear shafts in the same fashion as described in the "Intermediate Planet Carrier Assembly Service" section of this manual.
Remove the planet gears, bearings and thrust washers from the carrier.
Thoroughly clean and inspect all planetary components for damage or abnormal wear, as described in the "Intermediate Planet Carrier Assembly Service" section of this manual.
NOTE: Use care in handling the carrier to prevent damaging the hub on the gear side of the carrier, as this is a bearing surface.
Place each friction disc on a clean, flat surface, and check for distortion using a straightedge. The friction material should appear evenly across the entire surface, with visible grooves. Replace the friction discs if the splines are worn to a point, if the disc is distorted, or if the friction material is worn unevenly.
Place each steel brake plate on a clean, flat surface and check for distortion using a straightedge. Check both surfaces for signs of material transfer or heat. Replace the brake discs if distortion or heat discoloration is present.
Place each wave spring on a clean, flat surface. Check for distortion or damage and replace as required. Check the free height of each spring and replace if the measurement is .19 in. (4.8 mm) or less.
Install the bearing into a planet gear. Place a thrust washer on each side of the gear and insert the gear assembly into an opening in the carrier. Slide the planet shaft through the carrier, and into and through the gear and thrust washers.
Carefully align the pin hole in the carrier with the hole in the planet shaft, and drive a new roll pin into place. The roll pin should be recessed into the carrier to a depth of .53 in. (13.5 mm). Using a center-punch, stake the carrier next to the pin hole as previously described.
Repeat for each of the planet gears.
Position the carrier with the clutch end up. Lubricate the friction discs with new winch oil prior to assembly. Install a steel brake plate in the bottom of the carrier, aligning the tangs on the plate with the slots in the carrier. Next, install a friction disc. After the first friction disc, install parts in the following sequence: steel brake plate, wave disc, friction disc. Install the last steel disc.
NOTE: In the bottom of the clutch housing, there is no wave spring installed between the first brake plate and friction disc.
Install the thrust ring into the carrier on top of the clutch pack.
Apply light pressure to the thrust ring and install the retaining ring. Make sure the retaining ring is seated fully in the housing groove. The ends of the retaining ring must NOT extend into a slot of the housing.