Winch rebuild problems and lack of instructions.

[USN_Green_Addict]

My winch was jammed up and didn't want to engage so I decided to rebuild it. Truck is a 66 M35a2 was an M109a3.
After getting the winch off and taking out the brackets and hell of a bent up bar with a pipe wrench, I finally got the selector side off I've been trying to figure put how to get the PTO driven side with the gear off, but no success. I have the TM that shows all the parts with names. But it doesn't show proper assembly order. I also noticed on the selector side there is what i think is a brake pad attached to a T with a spring on the back. However where all the other trucks have the lever mine has a grease fitting. I still cannot get the PTO side off. Do I need to take the gear that looks like a screw out first? Im Also going to need another bar mine is bent to hell. Has anyone used thicker metal plates to replace the bent support bars?

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[USN_Green_Addict]

Forgot to ask how do i remove the woodruff keys on the engagement shaft side?

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[gringeltaube]

All the tricks you need to know to repair your winch can be found in this thread: https://www.steelsoldiers.com/threads/winch-teardown-q.80417/


Also, in this good old TM, Chapter 18 (starting on page 346) you will find very good images and detailed info on how to dis- and reassemble your winch.

Note: The 10000# Garwood front winch for the early M135/M211 Deuces is the same thing as what you have, there. (besides some minor differences nothing has changed over all those years).

 

[USN_Green_Addict]

Thank you for the TM I've bedn reading over it for a while. I've still not been able to dissemble it any further. I think mine might have a lot more rust issues than i thought. I still cannot get the drum off the shaft.

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[gringeltaube]

I still cannot get the drum off the shaft.

So, you did pull the keys out already? Does the drum move a bit at least, axially? Or does it feel solid with the shaft?

 

[USN_Green_Addict]

I couldn't get enough movement on either side to expose them enough try to remove them, unless all you need is for them to only be half exposed.

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[USN_Green_Addict]

Forgot to answer the other. With a pry bar I can get the drum. 1/2 inch apart from the gear side. I can turn the shaft independently of the drum and vice versa.

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[gringeltaube]

OK, just don't force anything! The sliding clutch collar (#7538691) needs to come out first; then both keys. After that, stand the assembly upright - gear case facing down - support it with your feet and pull up the drum.

 

[USN_Green_Addict]

This is the closest I can get it it in. And the furthest off.

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[USN_Green_Addict]

I can pick it up by just the drum and nothing happens

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[gringeltaube]

....I can pick it up by just the drum and nothing happens

Sure, because the keys are still in place...
As I said above, first that collar needs to come off the shaft; then you can/ must pull out both keys.

Make sure that the keys are not deformed or have any burrs that prevent the clutch collar from sliding further out.

 

[USN_Green_Addict]

Finally got that part off with the puller. Im trying the vice grips and punch unfortunately I just keep digging deeper bite marks with the vice grips. Any other tips to get these off?

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[doghead]

Hit the end of it with a drift punch.

 

[USN_Green_Addict]

Thank you just got the keys out now I cannot get the drum any higher than in this picture. Is there anything else inside that I'm forgetting to take out so I can get the drum off. Also how do you get the brake off?

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[USN_Green_Addict]

Status. I finally got it off with a wood block and a ton of hammering. Lots of Watergate out. The shaft will need a lot to be cleaned up its quite rough. Finally got a small enough puller to get the brake off. However I'm still working on getting the worm gear out. Should I clean up the shaft with emery cloth, never dull, ....?

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[gringeltaube]

Should I clean up the shaft with emery cloth, never dull, ....?

Yes. Also take a flat file and check the areas around the keyways. Any burrs/ high spots there will affect the drum bearing bushings when re-assembling.

 

[USN_Green_Addict]

Finally got the winch completely apart. Does anyone know where I can get the large gear? Or are chances the worm gear is toast as well?

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