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Old 03-12-2014, 02:36 PM   #1
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(Almost donewith Warn X8000i rebuild)

Rather than buy a new Chinese winch, I bought an old Warn X8000i for $250 off Craigslist. It didn't free-spool and was pretty ratty-looking, but otherwise it seemed to work. Taking it apart, I found the grease in the gears solid, rust inside the motor, and the drum brake in pieces. The gear packs were fine, but the sun gear had a lot of play. I replaced the gaskets, thrust bearing, drum bushings, brake assembly (numerous parts) motor ball-bearing and sun gear all for about $150 (mostly for the brake assembly $112), some sanding, painting and polishing and for $400, I have essentially a brand-new $1100 winch!






A couple tips for anyone doing this: I used vice grips to hold apart the motor brushes apart while I reinserted the rotor.




In replacing the sun gear, I also replaced the blind bushing in the end-cap. (sorry, no picture) To remove the bushing, I filled the hole in the middle of the bushing with grease, and inserted a socket and extension into the hole, then hammered it hard a couple times. The pressure created in the end housing popped the bushing out after a couple whacks. Easy!

Now I'm just waiting on new a new cable and decals to come in and she'll be ready to go!!

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Old 03-12-2014, 02:42 PM   #2
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Very nice post pics of finished product

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Old 03-12-2014, 04:26 PM   #3
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These are all over craigslist
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Old 03-19-2014, 03:49 PM   #4
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All done! Used a Smittybilt raised winch mount.

Glad I went this route. Saved an old winch. Stayed American.
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Old 03-19-2014, 05:29 PM   #5
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Nice.
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Old 03-21-2014, 06:37 AM   #6
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looking good! ive got an older XD9000 on my jeep that I should rebuild/clean up. Works great I just want to know the bushings and everything are good/new. ive rebuilt many 4-wheeler winches for work so I know how to do it, ive just been too lazy to take it off and tear it apart lol.
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Old 03-21-2014, 10:02 AM   #7
Knows a couple things...

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Very nice job on restoring that winch. You & I both know you could have bought a new Warn for less than the total cost you have invested but sometimes, it's worth knowing you did it yourself and you won't have to worry about it again. Heck I used to spend more to buy electronic kits (Heathkits for those old enough to remember lol) to make ham radio gear, stereo equipment, TVs, etc. myself than it would have cost to buy similar products that were ready to use but...
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Old 03-22-2014, 09:37 AM   #8
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Quote:
Originally Posted by Jerry Bransford View Post
Very nice job on restoring that winch. You & I both know you could have bought a new Warn for less than the total cost you have invested but sometimes, it's worth knowing you did it yourself and you won't have to worry about it again. Heck I used to spend more to buy electronic kits (Heathkits for those old enough to remember lol) to make ham radio gear, stereo equipment, TVs, etc. myself than it would have cost to buy similar products that were ready to use but...
Yep. I figure I could have bought a VR, maybe even an M8000 for the $$ I put into this, but no regrets. I guess in my maturity, I'm actually becoming "Eco". I just spent $50 in parts to fix-up a Bissell carpet cleaner that cost $120 ten years ago. I also buy new ink for my printers even though the ink costs half as much as the printers themselves. I hate this throw-away culture!

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