WArn WD900 Winch Modification

[leachy_9 Advanced Member Find all posts View Profile Close leachy_9]

I recently rebuilt a secondhand Warn XD9000. Along the way I made a modification to the brush and motor assembly to improve reliability.
The brush assembly is sandwiched between the motor frame and end cover and it is this joint that provides the brush earth circuit. Corrossion at this joint is a major source a motor failures. A modification to improve this electrical connection is to drill and tap (5/32" BSW) the motor frame and bolt the brush holder to the motor frame with brass bolts. As you can see from the pictures below there is very little room for error and I would not attempt this without a good bench drill. I got a lot of good advice and fantastic service from Malcolm Leslie at S.G Leslie and Sons in West Heidelberg Vic. I highly recommend them if you are wanting to either rebuild a Warn winch yourself or have it done for you.

Holes drilled and tapped.


With brush housing bolted in place.


Leachy

[Chippy Addicted PP Member Find all posts View Profile Close Chippy]

That's a real neat job Leachy .... now I've just got to take my winch back out

Maybe I'll wait until I need to service it :lol: :lol:

Bloody great idea though.

Cheers
Chippy

[MUMSRIG Avid PP Poster! Find all posts View Profile Close MUMSRIG]

That's a real neat job Leachy .... now I've just got to take my winch back out

Maybe I'll wait until I need to service it :lol: :lol:

Bloody great idea though.

Cheers
Chippy

With the amount of mud that you go through Chippy, it's probably time to do a service on your winch anywayz...

Mitch

[Guest Close Guest]

Please reduce the size of your posted pics to 800 pixels wide maximum thanks. Breaking the page.

[andrewh Junior Member Find all posts View Profile Close andrewh]

I'm currently getting some waterproofing done on a new Warn winch by Malcolm. If you are anywhere near heidelberg in Melbourne, I highly second Leachy's comments about Malcolm's knowledge and helpfulness. He's worth talking to. He can save you a breakdown when you least need it.