Well I needed to rebuild my Warn M8000 winch. This past weekend I pushed it to the limit and pretty much burned up the motor. After it cooled it still worked but I have no idea how it will react under load. All I know is it's sticky and it smells horrible.
My question is, should I just trash this motor or try and clean it up and stick it back in? I've already ordered the gaskets, bushings, decals and aluminum tie rods so the rest of it will be fine. I was thinking about getting some brake cleaner and doing what I can with the electric motor. If it doesn't work out then I'll just replace the motor.
don't use brake cleaner on the motor. If you are going to try and clean it up use a cleaner designed for electronics. Your local parts place should have something formulated for cleaning alternators
I'm going to try and find something today. One guy recommended the battery terminal contact cleaner but I don't think that's what I need. I'll try to find actual electronic cleaner if I can.
Unfortunately the more I look at it and think about it the more I'm leaning towards getting a new motor. I think this one is shot and if it does work it most likely won't be as strong as it use to be.
Wow! Hey, That's a bummer. Anyway, If it got all hot and stickey I would think that the insulation around the windings got to the melting point which is now thinner and likely to short out against the adjoining windings due to the thinness of the insulation. Might last or might not with a rebuild.
Lou, check out this link on Ebay. I asked the vendo if it was a replacement motor for your M8000 part number 77893 and he responded with this motor for $85.00 with $16.00 shipping. Hope this helps.
Man. Three jeeps, 4 winches, 2 burnt winch motors(mine too) and it still took over a hour and a half to get me out. Take good pics Lou, I'm doing mine soon.
How long and how extensively has you used your winch?
I'm getting a JKU Rubicon - adding front and rear off-road bumpers (so it'll be a little heavier than stock).
I was thinking about cutting costs and getting the warn M8000 (like you have), but the dealer recommended the 9500.
Here are my options:
• Warn M 8000 (82202191ac) = $825
• Warn XD9000i (82202612ac) = $1135
• Warn 9.5ti (82209325ac) = $1375
Any thoughts on which I should go with. I'll do some off roading, not entirely sure how many situations I'll be in that will require a winch, but I want one just in case... I guess having one makes you prone to needing it
I bought my winch used for $300 and that was about a year ago. It has already paid for itself in my opinion. It was a little rough looking when I got it but it worked so I bolted it on and wired it up. I'm kicking myself for not tearing into it when I first got it and cleaning it up.
As for which winch you should go with, that's up to you. The Warn M8000 has an external control box while the others have their solenoids internally stored plus the added pulling capacity. If you don't do any major rock crawling and don't get into sticky situations then get the Warn M8000. I burned up my winch motor by pulling my buddies massive CJ-7 100' up a 50 degree slope. Mine overheated and started melting the varnish on the windings.
I found a few in Atlanta but at the same time the housing is rusted and everything is charred. If I lived closer to a shop I'd go by and see what they thought. I might call and see what they say.
Edit: I also need to consider that it might cost around $50 for a rebuild or more plus the hour to drive there and an hour to drive back or I can get a brand new motor for $99 shipped to my door.
I found a few in Atlanta but at the same time the housing is rusted and everything is charred. If I lived closer to a shop I'd go by and see what they thought. I might call and see what they say.
Edit: I also need to consider that it might cost around $50 for a rebuild or more plus the hour to drive there and an hour to drive back or I can get a brand new motor for $99 shipped to my door.
I remember in the Fifties that gas was 19 cents a gallon, a one bedroom apt was $25 a month in NYC, cigarettes were 10 cents a pack and the minimum wage was 25 cents an hour!
I need to find a female pin connector. One of mine was caved in on itself which would explain why the controller would sporadically not work. I'm hoping I can find something at Radioshack.
I would think that you could use the pin from a trailer connector, but I don't know for sure.
Also, you might want to check out Pierce Sales. You can get a solenoid pack (2 double throw continuous duty solenoids that are intended for industrial winches) as well as the plug, remote, and solenoid to motor cables all for $60... Even if you just used the plug and the controller, that's not a bad deal and you'd have a backup option for your solenoids.
I've read others throwing out the idea of using a 6 HP motor to replace the M8000 4.2 HP motor. Can anyone confirm this? I'm going to keep researching since I haven't bought the motor yet. I'm still waiting on the rebuild kit from Warn. It should be here tomorrow. I've gotten everything else painted I just need the gaskets and bushings now.
It looks like you're coming along nicely Louie. I wouldn't think twice about taking on another spur gear winch, but I've only torn into a planetary once.... Whole different animal. I've always liked the compact features of the planetary winches, but there's a lot going on in there. It's good to see someone going through the trouble to save one rather than just tossing it and buying another.
I knew that Warn could supply replacement parts and from what I can tell they are durable winches with proper care. I don't think the last owner gave it the TLC it needed. Plus there's something I like about rebuilding versus just buying a new one.
I've asked around a bunch and most folks have said that they think my current motor just got hot and burned some of the varnish but it looks salvageable. I'm going to get some CRC contact cleaner tonight and see if I can clean it up and look into a electric repair shop.
OK. I've finally have a conclusion to this whole rebuild thing. I spoke with a electric motor repair shop in Knoxville, TN (my fiancé lives there) and I discussed with a technician about my motor and the situation I had. I told him the varnish got hot and some melted off. I said it was fairly black on the stator and inside the housing but it still worked after it cooled down. He asked if the commutator was smooth and if the brushes were in good shape and they were. I also said the rear bushing and bearing the shaft rides on were in good shape too. He said the varnish could have been black from upon manufacturing and said I should run it until it (not continuously but figuratively) until it stops working. I asked about a rebuild and he said that would cost more than what the motor was worth (he said between $200-300) and a new motor from Warn is $204 before shipping.
My plan is to clean the motor the best I can with CRC contact cleaner, paint it and bolt it back up. Then I'll run it until it stops and just get a new one from Warn. My only problem now is the socket plug on the control box cover. I tried the socket plug in the pics but it isn't long enough and sits down in the socket too far for the pin to reach. If anyone has a spare cover lying around I'll pay for it and the shipping.
OK. I've finally have a conclusion to this whole rebuild thing. I spoke with a electric motor repair shop in Knoxville, TN (my fiancé lives there) and I discussed with a technician about my motor and the situation I had. I told him the varnish got hot and some melted off. I said it was fairly black on the stator and inside the housing but it still worked after it cooled down. He asked if the commutator was smooth and if the brushes were in good shape and they were. I also said the rear bushing and bearing the shaft rides on were in good shape too. He said the varnish could have been black from upon manufacturing and said I should run it until it (not continuously but figuratively) until it stops working. I asked about a rebuild and he said that would cost more than what the motor was worth (he said between $200-300) and a new motor from Warn is $204 before shipping.
My plan is to clean the motor the best I can with CRC contact cleaner, paint it and bolt it back up. Then I'll run it until it stops and just get a new one from Warn. My only problem now is the socket plug on the control box cover. I tried the socket plug in the pics but it isn't long enough and sits down in the socket too far for the pin to reach. If anyone has a spare cover lying around I'll pay for it and the shipping.
Kool! Kinda along the thoughts I was thinking except.... I would have bought a new Motor for Peace of mind so to speak. Anyway, Good Luck and thanks for the Updates!
I'd definitely recommend putting a master control (power to the switch) and a two way momentary switch (for in and out) on the dash regardless of whether you get your remote up and running. I know that you typically have plenty of cable to run it to the cab, but it's awfully nice not to having to worry about snagging your slack remote cable with a tire... (don't ask, I was 17 and far less observant).
Have you considered replacing your plug with a trailer plug? It might not be as pretty, but it's more than sufficient electrically. I'm talking about the old round four pole style. On the winch side, it would look pretty much like it does now and nobody would ever see the plug end of the remote unless you were winching.
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