I just got a Warn CE XD9000i. It was installed on the seller's bumper, and was never used. The **** for the clutch doesn't rotate 180* to allow the drum to free spool, but it powers the cable in and out without a problem. I'm thinking of taking it to a Warn dealer to get looked at but does anyone have a simple tips to try out first? The pic shows how far the **** turns towards the free spool position.


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Its probably just lack of use tbh. Try giving the cable a good hard tug at the same time as you try to move the clutch lever to free spool. Mine sometimes is a little fiddly to get in.

 

Yeah lack of usage is what I'm thinking too. Right now I don't have a mount for the winch (waiting until next tax season for the RTE) so I'll have to think of a way to support the winch when I try your idea UP. Somehow I knew you'd be the first with a reply, just not that quick!!

 

You can also try, to move it to free spool whilst powering it in or out, but I dont recommend you try it a lot, just little "flicks" of the buttonin or outto see if it will engage free spool.

Dont wait for the RTE, put a discrete mount in !!

 

So I spent the better part of today rebuilding the planetary gears of the winch. Once I pounded the cover off I immediately saw what the issue was. The lower half of the gears were rusted and the lube looked like it turned into mud. After a long time of degreasing, and wire brushing as much of that junk off as I could, I added fresh Mobil1 lube and re-assembled everything. It works perfectly now!! I have no idea how the water or moisture got into the gears. The winch never installed (or used) by the PO, so it's not like it went through a river. Also, the other half of the winch (the motor) doesn't have a sign of any water damage at all. It makes me think there was something with the grease that was in there. Anyways, I found this great article on doing a complete rebuild of a Warn XD9000i online and used that to guide me. Before the winch is installed on my truck I'll need to replace the motor cap (it got damaged in shipping) and get new seals for the ones on the planetary gear side. Here are a few pics of what I found after opening up the case.


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Surely at some point that winch "must" have been dunked, there was a lot of corrosion in there for itto get to that state just sitting about.

Glad its all working now tho Clocks ticking dude, get it on the truck !!!!!

 

Any piece of equipment that just sits around will rust like that. It is the moisture that is in the air that does it.
Condensation. It will even rust a engine solid so that it cannot be turned over.
Sealed or not, the moisture is in there and if it cannot excape...