Step 1. Drain oil gear housing by removing plug from end bearing. Remove reducer and relief fitting.

Step 2. Remove air cylinder and gasket from gear housing cover by unscrewing capscrews. If new air cylinder is required, remove shim, nut and bolt from end of air cylinder rod and replace it. Apply Loctite to thread of nut and thread onto bolt to 3/8" from drive end. Use bolt and nut into end of air cylinder rod. Tighten nut against cylinder rod, keeping 3/8" distance from drive end of bolt to nut. If breather vent is damaged, remove and replace.

Step 3. Remove air cylinder adapter and gasket from gear housing cover by unscrewing capscrews.

Step 4. Disconnect tube from elbows on brake.

Step 5. Remove motor and gasket from brake housing by unscrewing capscrews. Replace gasket with new one during re-assembly. If necessary, remove valve from motor by removing capscrews. If valve is removed make sure two O-rings remain seated in their counter bores in valve.

Step 6. Remove brake assembly screws from brake to access mounting screws attaching brake to end bearing. CAUTION: Brake is spring loaded by clutch spring and must be restrained against end bearing as mounting screws are removed.

Step 7. Remove coupling and gasket from end bearing. Replace gasket with new one during re-assembly. Examine coupling for signs of wear, replace if necessary.

Step 8. Remove winch from upright mounting frame by removing capscrews, lock washers and shoulder bolts.

Step 9. Pull motor end bearing from drum assembly.

Step 10. Pull drum assembly upward from end bearing. Remove quad-rings from grooves in drum bearings. Remove input shaft, clutch spring and washers from end bearing. Examine key and input shaft for signs of wear, replace if damaged. Examine drum assembly for signs of wear. If splines inside of flange(drum drive) are damaged, the flange(drum drive) must be replaced. If bearings show signs of wear, replace by pressing old bearings from drum and removing O-rings from grooves in bearings. Place well oiled O-rings into grooves in bearings. Press new bearing into end of drum opposite flange (drum drive) and press bearing into flange until flange of bearing are flush against flange(drum drive).

Step 11. Remove output coupling and coupling shaft from end bearing. Examine bearings, pressed in output coupling, for signs of wear, If necessary, by pressing old bearings from coupling and press new bearings into each end of output coupling. Place coupling shaft into bearings.

Step 12. Remove capscrews to pull gear housing cover and gasket from ring gear.

Step 13. Remove input thrust washer, sun gear and carrier assemblies from inside of ring gear. Remove ring gear and gasket from end bearing. Examine shifter shaft for signs of wear, replace if necessary. Examine bearing in end bearing for signs of wear. Replace bearing, if necessary, by pressing old bearing from end bearing and pressing new bearing into place.

Step 14. Seat well oiled quad-ring into groove of bearing in each end of drum assembly. Carefully set drum assembly down over motor end bearing. Lift gear housing end bearing and set into place on drum assembly.

Step 15. Attach upright frame to end bearings. NOTE: determine mounting configuration of winch(R.H. or L.H. mounted) before attaching upright frame winch. Install shoulder bolts and hand tighten. Install capscrews with lock washers. Tighten inner-most capscrews securely, check rotation of cable drum. Tighten outer-most capscrews securely, check rotation of cable drum. Torque capscrews, in above inner-most then outer-most pattern, to 250 Ft.Lbs each. Torque shoulder bolts to 30 Ft.Lbs. each. Check rotation of cable drum assembly. It must rotate freely with no tight spots.

Step 16. Place end of output coupling, with longest splines, through end bearing and mesh coupling spline with spline inside of drum. Slide clutch sleeve over end and against shoulder of shifter shaft assembly. Place shifter shaft through washer and into coupling shaft, meshing splines of shifter shaft with splines in coupling shaft.

Step 17. Place ring gear onto end bearing, aligning holes in ring gear with holes in gasket and gear housing end bearing. Use 2 capscrews to temporarily secure ring gear to end bearing. Place 2 gear carrier assemblies into ring gear meshing carrier with ring gear. Slide input sun gear over shifter shaft and mesh with teeth of input carrier. Apply grease to input thrust washer and place into slots of housing cover. Place gasket into position on housing cover with sealer. Remove 2 temporary capscrews and attach cover with gasket to ring gear and end bearing .Use capscrews to secure gear box to gear housing end bearing. Torque capscrews to 39 Ft.Lbs. each, in criss-cross pattern.

Step 18. Pull rod from air cylinder as far as possible. Slide washer over bolt and against nut attached to air cylinder rod . Install air cylinder and gasket to gear housing cover using capscrews. Note: Place bolt into hole of shifter shaft. Apply Loctite PST thread sealer to threads of capscrews. Torque capscrews to 5 Ft.Lbs. each.

Step 19. Gently tap key into keyway of input shaft. Liberally apply grease to shoulder of input shaft. Place washer over end of shaft and against shoulder of shaft. Place spring over shaft and against washer. Slide clutch washer over splined end of shaft and spring. Use grease to hold spring and washers in place on shaft. Place splined end of shaft through drum and into output coupling. Mesh spline of input shaft with internal spline of coupling shaft inside of drum.
With pin installed in coupling, align keyway of coupling with key and end of input shaft. Slide coupling over end of shaft. Place gasket into position on brake mounting surface of end bearing. Insert brake shaft into coupling. Use 2 screws to attach brake cover/shaft assembly to motor end bearing. Torque capscrews to 85 Ft.Lbs. each.

Step 20. Re-attach brake module assembly to brake cover/shaft assembly using brake module assembly screws. Torque capscrews to 85 Ft.Lbs. Note: Care must be taken to assure cover and brake module are seated properly prior to installing 1/2"-13UNC assembly bolts. Damage will occur to rotor stack or shaft snap ring if not properly seated.

Step 21. Attach motor with gasket to brake. Use 2 capscrews and torque to 74 Ft.Lbs. each. Securely connect tube to elbow in bottom of valve and fitting in brake.

Step 22. Apply Permatex to thread of plug. Thread plug into tapped hole in bottom of gear housing end bearing. Pour approx. 4.75 pints of SAE 80W-140 oil into end bearing. Check oil level by removing oil plug. Insert relief fitting and thread reducer into end bearing at oil fill hole. Be sure relief fitting is not damaged. Replace if necessary. Bleed pressure release section of brake by loosening bleeder fitting on brake and allowing air to escape while slowly applying hydraulic system pressure to the winch.
Apply air pressure to the NPT1/8"-27 PORT:90 psi(Min.), 110 PSI(Max.), the drum can rotate freely. Remove air pressure from the cylinder and run drum until the clutch engagement and then the drum can't rotate freely.