Warn 9.5ti Winch Build Thread

[Midtenn]

I’m starting a build thread for my winch. Everything will start dumb because I have no idea what I’m doing, but I have infinite patience, curiosity, and am in a sufficient position to learn by doing.

I wanted a Warn winch not China made over Black Friday and instead just got this one out of interest and once back together, should be a solid winch for round about what I would have paid for a China one.

Initial investment was $100 off Facebook marketplace. It wouldn’t freespool, guy took it apart and lost interest.

here are some pictures

My plan is to get it working, then disassemble again for paint. Reason for doing it that way is odds are it won’t work on my first try so I want to wait until it works for paint.

 

[Midtenn]

First issue is the roller fairlead won’t bolt up. Not sure why.

Rest of everything else just needs to be cleaned really well. Next trip is to get a small bucket or maybe it’s time for a parts washer.

 

[Got4wd]

That’s not a warn fairlead

 

[Midtenn]

That’s not a warn fairlead

yep. I did some research and found out it’s a smittybilt. I’m hoping that’s the biggest issue. What I’m trying to figure out now is how to get the motor back together to test it.

 

[Got4wd]

Any new progress pics. Winch looks rough. Hope it comes out working well!

 

[Blackjack]

Before you get too far into your build, take some time and make sure you can bring the motor back to life. From there you are going to need a new brake, seal kit, bushings, and I did not see the first stage planetary. It needs to be checked to make sure the output gear is still firmly fastened to the side plates.

 

[Midtenn]

Before you get too far into your build, take some time and make sure you can bring the motor back to life. From there you are going to need a new brake, seal kit, bushings, and I did not see the first stage planetary. It needs to be checked to make sure the output gear is still firmly fastened to the side plates.

Can you explain this a little better? I understand the part about the motor, but not the gears.

 

[Midtenn]

Any new progress pics. Winch looks rough. Hope it comes out working well!

Not yet. All the gears are getting prepped for a chem dip. On Wednesday, I plan on getting some leads to be able to test the motor.

 

[Blackjack]

Can you explain this a little better? I understand the part about the motor, but not the gears.

You need to check this connection on the first stage planetary. It is used as the brake driver on your winch and can fail if the winch is abused.

 

[Midtenn]

You need to check this connection on the first stage planetary. It is used as the brake driver on your winch and can fail if the winch is abused.

View attachment 208613

Thanks. I just found this piece. I’ll check it out.

 

[Midtenn]

Mine looked good and is now going into the dip. The concern I have now is with the bearing on the end of the motor. I’m not sure if I can press this off or not.

 

[Blackjack]

You will need a very small bearing knife but it can be done. The easiest bearing to find that works it a 202ff.

 

[Midtenn]

You will need a very small bearing knife but it can be done. The easiest bearing to find that works it a 202ff.

Based on what you see, you you bite the bullet and replace the motor? That kills making this a good deal but seems inevitable at this point.

 

[Zorba]

Based on what you see, you you bite the bullet and replace the motor? That kills making this a good deal but seems inevitable at this point.

I wouldn't. Worse case you destroy it getting the bearing off (which I don't think you'll do).

 

[Mike_H]

Nice. I scan Facebook occasionally, looking for a deal on a used Warn to bring back to life. I have a Smittybilt, but I'd like to replace it with a Warn someday.

 

[Midtenn]

Any idea what these pieces go to? They aren’t on the diagram anywhere.

 

[Midtenn]

Nice. I scan Facebook occasionally, looking for a deal on a used Warn to bring back to life. I have a Smittybilt, but I'd like to replace it with a Warn someday.

Today there’s a BNIN smittybilt 9500 with synthetic rope for $250. Restoring this joker is a hobby, I’m not sure you can make it financially worth it.

 

[Zorba]

Any idea what these pieces go to? They aren’t on the diagram anywhere.

View attachment 209150

View attachment 209151

View attachment 209152

Brake shoes from the in-drum brake.

 

[Mike_H]

Today there’s a BNIN smittybilt 9500 with synthetic rope for $250. Restoring this joker is a hobby, I’m not sure you can make it financially worth it.

Absolutely not financially worth it. It's a fun project though, and it keeps me from sitting on my ass watching TV. Just putting the finishing touches on this. 1964 Simplicity Broadmoor. In no way did it make sense to restore this tractor... But I like the style and I had it... So why not?

 

[Blackjack]

Based on what you see, you you bite the bullet and replace the motor? That kills making this a good deal but seems inevitable at this point.

Need to inspect the motor case and brush set and make sure they are in good working order.