Anybody stuck with a problematic winch needs to watch this video before attempting anything on their unit! Hands down one of the best technical how-to ever!

Whoever give this a thumbs down shame on you and let's see how much better you could do this is a very good video cost you a lot of money to repair a winch and seeing how to do it yourself take step by steps is awesome thumbs up a hundred thumbs up for me in the states

Thank you again, your videos are the most informative on the web, and very easy to understand for us unskilled DIY ers keep up the good work.

Great series...Am about to rebuild a Warn M8000, and not only learned heaps from your tutorials about how to do it, but learned even more about what I didn't know that I had to know! Greets from SW Oz!

Fraser; This is hands down the best instructional video I have ever seen on you tube. Warn charges a lot for repairs. They get a high minimum just to look at the winch before you find out what the cost of repairs will be. Plus in my case I would need to ship them the winch (not cheap given the weight and distance). Frankly it is cheaper (or at least less risky) to replace the winch at a cost of nearly $600 than go through all that. My winch now works like new. Thank you. You just saved me hundreds of dollars!

An excellent video, not only explaining the diagnostics and remedy, but also the pitfalls to avoid. Better still near me in Devon!

I am on the market for a 90 and have just been looking at a lovely grey car on the Devon 4x4 autotrader page, complete with winch. Which lead me to have a look at winch servicing on KZfaq, and then I notice your Polo shirt and what’s written on it ! Really useful video, thank you.

This was super helpful and easy to follow. Thanks for showing and not just talking!

You're Great!!!!! I´m in debt with you. Just repaired my winch thanks to you. I´m in Argentina, there is no Warn representative and due to the actual situation we cannot get spares Again. thanks!!!!!!

Very good Sir! I am a Master Builder at Warn Ind. In Clackamas, Oregon I am now one of two Service Center Technicians at the main building. Really, we're just a couple guys that have been building winches for years and now fix them. We wheel! Did the Gambler 500 back in 2019. While you are spot on and taught me a trick that I'll use, try taking the tie rods off first and building the gear train with the drum support down. Cheers!

Thank you for creating and uploading the videos. My winch stopped working and I was able to fix it after watching this series. In my case I found water and mud inside the motor and the brushes were stuck. After cleaning and putting it back together it’s working like new again. I would buy you a few beers if I was closer to you. Thanks!

Nicely done. Thank you for taking the time to video this.

Outstanding!!! Thanks, mate. One of the finest, most intelligently conceived and executed instructionals I've seen on this platform. Brilliant, yet accessible to us reg'lar folks. I've just purchased a used Warn M12000 - clicks, but no motor engagement. Had it partly disassembled, but was stumped, when I stumbled across your video (thanks, KZfaq algorithm). It's like I was stuck up to my axles in muck and some good soul came by and winched me out. Can't thank you enough.

Great three-part video series!!! Plan to clean-up, repaint, and re-lube my 20-year-old Warn M12000 and change-out the solenoids (SAZ-4201EY). It is rusty and noisy but turns in both directions when connected directly to field and armature terminals. THANK YOU!!!!

Very good video. Does a very good explanation on everything. Haven't taken winch apart yet but now I know what to do. Thanks again

Thank you, very helpful video. I had this problem with mine and was afraid to go into it . But watched this and it's good to go

Wonderful video. I got my winch back from the repair shop only to find the spool would not engage. After watching all three parts, I took my gear box apart to find the internally toothed sleeve was installed upside down, so the engage lever couldn't line up with a detent and engage the spool. Different brand, but very helpful. Very well done. Thanks for posting.

Great video. You explain things really well 👍🏻

I'd have started with a good power washing. Of course, it depends what the customer was quoted for work, yeah? He makes a good point of not using penetrant only water. Before assembly throw everything on a sheet pan and bake it like a roast. The commutators and stator windings can handle it. I might add that the varnish on the winding is broken down with any petrol based cleaner. Just water. He's doing good work by not attempting to solder that looks connection. The minute you put any load on the winch, the solder will melt. If the customer approves and wants to try to solder the connection the entire stator housing must be dipped in it's entirety into a varnish tank and banked. It's not the repair that is the problem, its properly isolating the repair. Great proper video with sound principles employed.

Thank's a lot! Helped me so by repairing my winch. Cheers from Germany!

Thanks you have a lot of Patience and very informative Regards Joe

Great Video. I bought a defender to replace my stolen one and it came with a very battered looking XD9000i I was going to bin it until i saw this Saturday night. Carried out the poweron test Sunday and its dead as the proverbial Dodo.Time to explore. Split the motor from the winch. Ye gads, the amount of sand in the motor was ridiculous. The end bearing was seized as well. Electrically though it is sound. Bushes have hardly worn at all. Think this may be a little project for the next few weekends. Just need to split off teh gearbox tonight to see if its worth continuing. Thanks for the video. it was so informational.

Thank you Frazer for such high quality maintenance videos. This will enable me to do mine with complete confidence.

This is the best tutorial on U Tube

Legend! Helped me sort out my dead winch. Cheers from Australia!

Best Video ever... thank you so much from Paraguay

Excellent video, thanks for posting!

Very well explain thanks for the information thanks a lot good job

excellent video, thanks.

Great Help. Thanks!

excellent video, thanks!

Great job. Thanks man.

Very nice, thanks a lot!

Can you tell me why these type winches used to have 2 leads on the motor and now have 3? On the 2 lead it was easy to jump them if the solenoid failed but the 3 is more complicated. This is a fantastic how to series!

Just the video I needed. Cheers

I just opened up my 9 year old superwinch talon. Despite living in a desert with less than 10in of rain per year and having never been submerged, everything inside my winch is covered in thick rust and severely pitted. Even though the winch is supposed to be completely sealed and water proof.. Hopefully the company that bought superwinch will honor the warranty.

Really good video to take the cover out of the end of the motor you can take the little white plug out from end of cover hole is threaded so you can put a screw that push the cover out no need for bashing.

The solenoid check using a test lamp confirms the solenoids are able to pass enough current to the illuminate the test lamp but this doesn't mean the solenoid contacts are in perfect condition. A test lamp may only draw 5 watts or so. The winch motor may draw 50 or 100 times more than that without a heavy load. Still it's an important test to check whether the solenoids are totally shot before you progress any further.

Thank you for the great teaching! One remark: to my best knowledge it is a series dc motor (no magnets). Regards from Brazil and thank you again!

Very good video !

Excellent , thanks

I appreciate the video. It seems to me that cleaning the exterior of mud would minimize the chances of contamination once you open it up. A damp rag would do nicely.

Thank you for the maintenance clips for the winch. I want to ask you. I have an American Warn winch. It seems that there is a problem, and it is during the towing. It works. When the towing stops, it loosens and returns the trailer and does not continue to the state of tension. One of the technicians told me that the winch clutch must be changed, so is what he said correct. Thank you

Is it an issue with a cracked control pack with rain/water getting in? Thanks for your help in advance.

Great Videos.. Helped me Immensely with teardown of My Harbor Freight Mod 44006 440/880 Lb Hoist... It has a few design differences and that's where I need some advice. Symptoms- Hoist would only Hum and not move up or down. No solenoids as the one in the video just two Capacitors (Up/Down?) Disassembled and No Brushes... Rotor and stator turns freely after removal from the spring loaded Brake Hub/bearing assy.. but that assembly is stuck inside the Fan Cover. Parts breakdown shows Break hub,bearing and cover separated. I'm thinking they overheated and froze together. Anyone disassembled one of these types before? Bearing spins freely inside cap but..is brake hub supposed to spin? I don't want to force them separate unless I know if they should. Thanks for any advice.

Hi from Oamaru Sth island New Zealand. OkeeDokee the grease used and specified is Aeroshell from Shell oil company. What other grease grade can one use?. It's metal to metal gears so will molybdenum disulfide grease do?. Im trying to find a grade the Amsoil may have that suits. Thank you for the time u took making and delivering to the world this video. Cheers Carl.

fantastic, I can get my warn going again

Good video thank you ....

this help me dissasemble a friends winch and find that one of the wires/copper bars connecting from one field winding to the next was blown apart, cheers

Can you please tell me what grit emery cloth are you using ? Thanks

Excellent video. Anyone know how to attach the A-post back to the copper wire inside the motor?

My solenoids make a really chattery noise both winding the winch in and out. The winch doesn’t move. I’m not getting any voltage across the solenoid terminals. I assume I’m up for brand new solenoids.

All good advice, but my brushes are seized in and won't move. They are quite brittle. Any tips to get them out...

If I just put a tester on the live terminal of the motor and switch it on and it registers 12v but the winch won't move and I have a good earth, won't that be enough to tell me the motor is seized?

Ami wuinch se le despegaron los imanes i se quebraron tuve que conseguir otros más anchos pero a hora no funsiona que puedo aser

u have any video about brake assembly for this same winch?

Has anyone found a place to buy the brushes for these? I have one that cooked one brush wires and all warn sells is the whole motor 🤦🏼‍♂️

Wondering if anyone could me out. Have the exact same winch. At 17:40 in the video when you take the end cap off the motor mine is completely stuck. I can tap it away from the rest of the motor body but i cant get it to come off it just rotates. Any help would be appreciated.

Hi friend, Nice video, i have a question, i have a superwinch hidraulic h8... Can i change that hidraulic Sistem by electric motor

Good tutorial. Have you considered using gloves while you work?

Como armar wincher watt genérico

Mine spools in no problem just not spooling out unless its free spool and pulled out any sujestions

Seeing how filthy winch is. What kind of a mess is the rest of that vehicle?

Thank you for the good video, sir. I have a question. Is there any way to use the "car winch" at home? (sometimes to lift a heavy object) I think I can use winch like this with my short knowledge. Will you check my thoughts? Connect the battery disconnected from the car to the winch, then connect the battery connected to the winch to the battery charger and plug the charger into the 110V in the house. What do you think of this method? And I saw a comment saying that connecting the winch directly to a battery disconnected from a car can overload the battery, which can shorten the battery life and be dangerous. Is that really so? If you know the answer to this question, let me know... Thank you.

I have a question. i got to the point to remove the endcap of the motor. here i'm stuk i can freely turn it so no rust but it wont come of. is there something i'm missing here?

the end cap of my electric motor is cracked bad and the bearing froze. I need to find a used motor that is toast so I can use the cap on my motor. It is a Warn M8000 anyone in the Ohio , Michigan, western Pa , WV. Eastern Indiana .........lmao anywhere in the states I am interested

and i own a land rover 5 door safari 1971!!! huge coincidence

Sounds like the rock guy on ragnarok

They make "electric motor parts cleaner" in spray cans. That works great for cleaning the brushes.

My name is Fraser!!!!

Mine sat for 20 yrs. lol It's a dual winch. One works great although I have not tried to engage free wheel.. The other side's motor sounds great. But it's stuck in free wheel. I can't get the lever to move by hand. Haven't really got serious about it yet. Any suggestions?