Warn 9.5ti motor rebuild

[proper4wd]

I have a ten year old 9.5ti that I am in the process of rebuilding/refreshing. I want to have the motor gone through because when I last used it 3/4 years ago it was sparking and arcing. Does anyone have experience going through one of these motors that could offer insight or am I better off sending it out?

 

[ExploringNH]

I have a ten year old 9.5ti that I am in the process of rebuilding/refreshing. I want to have the motor gone through because when I last used it 3/4 years ago it was sparking and arcing. Does anyone have experience going through one of these motors that could offer insight or am I better off sending it out?

Where was it arcing and sparking from? Typically the motors are pretty good unless they were sitting filled with water. Was it for sure the motor itself? You can get new bearings and brushes for them and they are fairly simple to replace. If it is a problem with the windings you are probably better off to get a replacement.

 

[Thirty-Nine]

Also, don't hesitate to contact Warn, as they're usually very helpful with this kind of stuff: 800-543-9276.

Andy

 

[proper4wd]

From what I remember, I saw yellow sparks shower out from the motor assy and also a blue arc from the motor case to the cast alloy motor shield. Both were intermittent and the winch continued working.

I am going to take the motor apart tonight and see what I find. I have the rest of the winch in pieces so might as well!

I'm also investigating getting rid of the 4 internal solenoids in exchange for an external Albright contactor. I don't like the non serviceable nature of the internal solenoids (you have to split the winch case in order or remove/replace individual solenoids).

 

[proper4wd]

I took the motor apart tonight. It had a good amount of corroded white dust inside. The electrical components look fine though, I will just clean some things up with a bit of emery cloth. I did find that the bearing on the cap end of the motor is junk so I'll have to replace it. Would an oem Warn bearing be best or is there an upgrade opportunity here?

 

[ExploringNH]

I took the motor apart tonight. It had a good amount of corroded white dust inside. The electrical components look fine though, I will just clean some things up with a bit of emery cloth. I did find that the bearing on the cap end of the motor is junk so I'll have to replace it. Would an oem Warn bearing be best or is there an upgrade opportunity here?

I don't feel there is any need to upgrade that bearing but a possible cheaper alternative might be found.

Bench test it before installing it to make sure everything works as it should. It would be a shame to get it installed and have the same issue.

 

[proper4wd]

What is the best method for pressing the bearing on and off the stator? This is my first time messing around with the internals of an electric motor and I don't want to damage anything.

 

[ExploringNH]

There isn't anything special about it. Use a press like a normal bearing with the bottom of the shaft supported, not the windings. You can also hammer it on, again supporting the shaft. I remember you being pretty mechanically inclined so I wont go into all the details about making sure it is flat going on and to only put pressure on the inner race and only use the necessary amount of force, dont go too far with it, etc. If you do need a step by step, let me know. The main difference is in how the whole thing is supported while the bearing is pressed on. The motor shaft is solid and runs through everything. Support the bottom of it and you are all set.