Is the Warn XD9000i a good winch?

Electrical looks good, but I’ll have to test everything to make sure the solenoids are good.

Might need a new remote since the Evil Winch Doctor said these weren’t the best and one of the pins is slightly recessed.

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The drum looks good. Corrosion and rust on each outer end. I removed it all and gave each end 2 coats of clear. I’ll paint the inner part of the drum tomorrow.

I ordered 4 new electrical boots and the special grease @Blackjack mentioned. I also got 4 3/8-16 square nuts and 4 3/8-16 1 1/4” bolts with lock washers to bolt it to the Warn Rock Crawler Bumper! There were other odds and ends I needed and got those on the bench waiting.

@Blackjack is sending me the insulators, bus/bar, and a lot of other stuff I need to restore it to good working condition. Stuff that I can’t find or is hard to get. I’m really thankful he has a penchant for these winches because he’s been very helpful.

Oh, and one more pic at the bottom. That’s what I found when I opened the electrical. 🤨

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Before I forget you will not want to mix the new grease with the old so just use the new stuff on the bushings since the gears look good.
 
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The drum was cleaned of all rust. Self-etch primed, satin black enamel and 1K gloss clear. @Blackjack is sending me a number of parts. When they arrive I will get it all back together, strip, mask, prime, paint, and matte 1K clear. I emailed Warn to tell them I’m resto’ing an xd9i and requesting decals. We’ll see!

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@Blackjack

I need one of these where the cables pass into the housing.
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I ordered new electrical boots. How do you put the new ones on the cables?
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Prepping the outer housing for fresh paint. I think I’m going to use a metallic black or straight satin. I thought about going back to the factory gray, but it doesn’t really go with anything on my Jeep. 🤫

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People who paint over stickers suck.

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I also really love the people who paint bolt heads so I get to clean all the paint off. 🙄

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@Blackjack, you mentioned doing something to slow corrosion on the motor. What we’re you talking about?
 
@Blackjack

I need one of these where the cables pass into the housing.
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I ordered new electrical boots. How do you put the new ones on the cables?View attachment 324518
That grommet is PN 27124 I do not have a good one right now but Six States can get you one or Montana Jacks has one in stock. The boots slide on the cables with a little effort. Make sure to grab some Ultra Seal from Six States to protect those connections.
 
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@Blackjack, you mentioned doing something to slow corrosion on the motor. What we’re you talking about?
It will make sense when the mailman drops things off but I will say you need a tube of either Ultra Black or Ultra Grey Permatex depending on what color you are painting the motor.
 
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It will make sense when the mailman drops things off but I will say you need a tube of either Ultra Black or Ultra Grey Permatex depending on what color you are painting the motor.
Oh, to cover that hole between the end cap and motor housing. Got it! I still have some of The Right Stuff - 1Minute gasket maker.
 
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I remember Earl Scheib when they did a complete car paint job for $99.95 in the 80's. Door seals and everything got painted. :LOL:
Yep too much time and money to mask stuff off. In the heavy equipment world they call it a Ritchie Brothers rebuild named after the auction company.
 
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I remember Earl Scheib when they did a complete car paint job for $99.95 in the 80's. Door seals and everything got painted. :LOL:
We had an chain outfit in California in the 70s called "Autorella" - make your car a Cinderella, $79.99 full paint job. Just like you describe: Minimal to no prep or masking!
 
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Dang I missed following this as I have a bag of the boots I'd bought to do my rebuild.
 
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