Warn 9.5ti service

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   I tried to use my winch on my last offroad trip, and it didn't want to take in the cable.  It's almost feeling like the gear is trying to engage (I flipped the lever to the retract position), but not quite syncing up enough to work.

Does anybody have experience with working on the 9.5ti's and willing to show somebody how to service/maintain them?

I'm sure it will require some new parts, but I don't know the first thing about tearing into a winch and I honestly don't want to mess it up since it is for safety/recovery.

Yes, I'm sure I could take it to a service center (are there any here in town or close by?), but I wouldn't think the work that difficult to do if you know what you're doing.

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erickpl Members Profile Send Private Message Find Members Posts Add to Buddy List RCRC Club Visitor Joined: 10 December 2004 Location: United States Status: Offline Points: 550	Post Options Post Reply Quote erickpl Report Post Thanks(0) Quote Reply Topic: Warn 9.5ti service Posted: 14 November 2014 at 5:38am
	I tried to use my winch on my last offroad trip, and it didn't want to take in the cable. It's almost feeling like the gear is trying to engage (I flipped the lever to the retract position), but not quite syncing up enough to work. Does anybody have experience with working on the 9.5ti's and willing to show somebody how to service/maintain them? I'm sure it will require some new parts, but I don't know the first thing about tearing into a winch and I honestly don't want to mess it up since it is for safety/recovery. Yes, I'm sure I could take it to a service center (are there any here in town or close by?), but I wouldn't think the work that difficult to do if you know what you're doing.

alabamatoy Members Profile Send Private Message Find Members Posts Add to Buddy List Admin Group I dont work here anymore... Joined: 16 February 2004 Location: Signal Mountain Status: Offline Points: 9442	Post Options Post Reply Quote alabamatoy Report Post Thanks(0) Quote Reply Posted: 14 November 2014 at 6:47am
	My experience is these things are really simple. They are a big motor, a sliding dog style clutch and a bunch of relays. I haven't taken that many apart, but my limited experience has been that the lubrication in the thing turns into something like Johnson's paste wax and it just wont work right until you clean it out and re-lubricate it. Take off the screws that hold the non-motor end cover on, and pull it off. Use your cellphone to take pics to help you get it back together right. The electric motor has a shaft that passes through the drum. Its a very simple device. I be you find that the sliding dog clutch is gummed up with decayed lube or something else in there.
	"If you didnt buy your 1st gen 4Runner new, then YOU are a newbie!!" BRC Life Member

alabamatoy Members Profile Send Private Message Find Members Posts Add to Buddy List Admin Group I dont work here anymore... Joined: 16 February 2004 Location: Signal Mountain Status: Offline Points: 9442	Post Options Post Reply Quote alabamatoy Report Post Thanks(0) Quote Reply Posted: 14 November 2014 at 6:52am
	One more thing... When you move the lever to engage or disengage, its actually sliding the dog gear on or off (or in and out) of the motor shaft gear and drum gear. I saw one where that level had been broken off at the internal end where the dog was no longer being moved. My big one (16.5) will often not engage correctly and you gotta bump it with a slight pressure on the lever to get it to engage. That lets the gears line up while the dog gear has pressure on it to move.
	"If you didnt buy your 1st gen 4Runner new, then YOU are a newbie!!" BRC Life Member

98TJ Members Profile Send Private Message Find Members Posts Add to Buddy List RCRC Club Member RCRC Club Treasurer Joined: 10 May 2005 Location: Maysville, Madison County Status: Offline Points: 8926	Post Options Post Reply Quote 98TJ Report Post Thanks(0) Quote Reply Posted: 14 November 2014 at 10:36am
	http://www.greatlakes4x4.com/showthread.php?t=69556 http://www.jeepsunlimited.com/forums/showthread.php?305588-my-9-5-ti-is-busted-wont-free-spool http://youtu.be/jr5yY53FbYA Edited by 98TJ - 14 November 2014 at 10:43am
	1998 TJ 4.0 5spd Atlas 36" Swampers RE4.5 ARB's 44/44 2015 JK Rubicon, mostly stock

Toydawg Members Profile Send Private Message Find Members Posts Add to Buddy List RCRC Club Visitor Joined: 20 June 2006 Location: United States Status: Offline Points: 953	Post Options Post Reply Quote Toydawg Report Post Thanks(0) Quote Reply Posted: 14 November 2014 at 11:53am
	If it only powers in or out (but not both) you can have a bad solenoid. Links below for checking solenoids and rebuilding the 9.5 XP. https://www.youtube.com/watch?v=MbW5-Yvz_qk https://www.youtube.com/watch?v=BADjA0t0g8I
	1984 Toyota pickup, locked 5.29s, dual cases, Longfields, 22R with low range cam and header.

erickpl Members Profile Send Private Message Find Members Posts Add to Buddy List RCRC Club Visitor Joined: 10 December 2004 Location: United States Status: Offline Points: 550	Post Options Post Reply Quote erickpl Report Post Thanks(0) Quote Reply Posted: 19 November 2014 at 9:12am
	Thanks for the links. I'll look at those and then take the winch off a give it a shot. A few years ago I had a trail collision with another Jeep and my light bar folded back into the winch and bent the winch plate a bit. I'm kind of wondering if the slight bend in the winch plate may be causing a bit of a bind. So before I do anything, I'll unbolt it from the Jeep and see if things work normally. If so, that will be #1 done. Then I'll probably still open it up and clean it out as I haven't done maintenance on it at all since buying it. If it IS a bent bumper/winch plate, I'll have to figure out how to either straighten it back to normal or put a regular winch plate over it. That second option may leave a gap though and I'd worry about gunk getting stuck in there and rusting out. One step at a time I guess. :) I do appreciate the input. I figured they were pretty simple to put together, but worry about having everything line up properly.

erickpl Members Profile Send Private Message Find Members Posts Add to Buddy List RCRC Club Visitor Joined: 10 December 2004 Location: United States Status: Offline Points: 550	Post Options Post Reply Quote erickpl Report Post Thanks(0) Quote Reply Posted: 23 September 2015 at 8:34am
	Finally getting around to working on this. The motor will engage, but nothing will turn in either direction. I'm thinking that it is along the lines of what alabamatoy said about that clutch not fully engaging when I turn that lever. I'm ordering a new set of gaskets, washers, and seal kit to address this stuff. That GreatLakes link has pretty much what I need. Hopefully this takes care of everything! The parts I'm ordering: 13826 Thrust washer 13848 x 2 housing gaskets 64642 seal kit and maybe 64640 motor cover (since it is cracked and looking like crap). May also order 64637 Control assembly cover since it has a crack too and that crack may be letting more casual moisture into areas I want to keep it out.