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Warn 8274 rebuild.....Project Mall Crawler, parking lot extraction device is done!

If you have the newer style solenoids (which are now called contactors) which look just the ones in the picture you posted, just call warn or a warn service center and they can get them for you as they still use them in ALL their winches.
 
If you have the newer style solenoids (which are now called contactors) which look just the ones in the picture you posted, just call warn or a warn service center and they can get them for you as they still use them in ALL their winches.

I called warn... and in the process added another $55 to the build cost. I bought 4 copper bus bars and their labeling kit ($37 kind of crazy... but all well)
 
Just new stickers...etc. I'm not sure exactly what's in there. We'll see...

LOL.... I FINALLY got my rebuild parts in from Warn. The $37 labeling kit turned out to be just this:

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I'm not sure what I was expecting... but I figured for that much it came with a new plastic solenoid cover. If the sticker fit my model I would've sucked it up and used them, but they cover up the serial number on the older models like mine. All well... its all back in an envelope now heading back to warn with a RMA number. I refuse to spend that much for just these stickers.

Now off to my box of parts to start the rebuild....
 
See the following pics of my progress. I have a few questions related to these pictures:


  1. Does my oil seal on the brake shaft look right?
  2. What the heck is that cardboard spacer used for anyway?
  3. I painted the brake parts, but I'm thinking the insides (the parts that contact the brake discs should be bare metal. Am I right?
  4. I have 2 lines coming out of my new motor that wasn't on the old motor. I think they are ground wires, but what do I do with them?
  5. I don't have bolts/nuts to actually attach the winch to my bumper. Do I need specialty nuts, or can I slip some grade 8 nuts behind there. Or... are the holes suppossed to be threaded?? If they are... I may need to tap and thread some new holes.


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Hope this helps

Does my oil seal on the brake shaft look right?Yep, its installed correctly
What the heck is that cardboard spacer used for anyway?Its a wear spacer
I painted the brake parts, but I'm thinking the insides (the parts that contact the brake discs should be bare metal. Am I right?Correct, leave the inside parts bare
I have 2 lines coming out of my new motor that wasn't on the old motor. I think they are ground wires, but what do I do with them?No clue on the new motor, never seen one with two wires coming out like that.
I don't have bolts/nuts to actually attach the winch to my bumper. Do I need specialty nuts, or can I slip some grade 8 nuts behind there. Or... are the holes suppossed to be threaded?? If they are... I may need to tap and thread some new holes.You don't need grade 8 for the winch mount, just get some grade 5 bolts and you'll need SQUARE nuts for those as they fit inside the feet
 
A wear spacer? I don't get it. Is it supposed to stay there? or is it just temporary while you install the brake? It is cardboard after all....
 
A wear spacer? I don't get it. Is it supposed to stay there? or is it just temporary while you install the brake? It is cardboard after all....

I just found this quote on another site:

"The cardboard is used to install the bushing and oil seal, and then removed after the brake assembly is driven into the lower housing. "
 
Maybe I should of been more clear on my description of wear spacer :doah: But your quote you found is correct.
 
I left my cardboard ring on... I'm sure it's disintegrated by now.:D

I would like to get the new motor for mine though, kind of curious about the two extra wires.:thinking:
 
Ok, winch is on the recently installed bumper. I'm still trying to finish up the wiring here. I'm not using a WARN controller. I'm only installing an in-cab switch. I have two main questions:

1) Is my ground wire hooked up the the motor mount bolt ok, it runs back to the battery.
2) There are two brown wires coming out of my motor, where to they go to?

I modeled my wiring based on this diagram:
schematic2.jpg


Here is where I'm at now.
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But then I found this one, and I see brown wires I haven't dealt with yet (this graphic is upside down)

Ok... have another question..
Should I run the brown wires across the solenoids as pictured? Then attach the wires from the motor to these terminals?

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Not sure about the brown wires either. Never ran into them before. Hopefully someone here has.
Can you tell what they are hooked to in the winch motor?

Given their size, I suspect that they are hooked to a temperature switch that will kill the solenoids when the motor gets too hot.

As far as the wiring is concerned, try checking out post 6 in this thread.
http://coloradok5.com/forums/showthread.php?t=247899&highlight=winch

Study it carefully, and you will see that to power the winch in one direction, one F wire gets hooked to the Arm wire, and the other F wire gets hooked to the battery.

To run it in the opposite direction, the two F (Field) wires just reverse positions.

As long as you can get the solenoids to do that, you are in business.
 
I ended up just ignoring the brown wires. I got it all wired up and installed. The only thing left to do is seal up the case with some RTV.

Project Mall Crawler, parking lot extraction device is done!

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My in-cab switch:
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Looks really good.

As for the brown wires, given their size, the only thing they could be is a thermal switch.
You would wire them in series with the power input for the coils of the solenoids. That way, if the motor overheated, it would kill power to the coils and thus kill power to the winch.

As long as you don't hold power on while its stalled, and don't do super long winch pulls without checking on the motor temp, you should be ok.

If the motor starts to smoke, stop.

To an old timer like me, its really funny to see folks bragging on and looking for those winches.

When they first came out, they were widely regarded as junk.
Around these parts at least.

My friend who built winches had a pile of them behind his shop that he had taken off to put one of his own.

At first, he gave a little trade-value for them, thinking he could make a good winch out of them.
They were so much prettier and nicer looking than his. But every attempt to make them pull to his level failed.

The last attempt, was to adapt a Ford 6V starter motor to them like we used for our winches.

Got it adapted, mounted the winch on the test bed, hooked up the big bus battery and fired her up.

It was looking good for a few seconds. Just when he thought he had a working idea, the gear box exploded!
After that, if someone wanted to do a trade, his only concession was to take the old one off for free.

The customer could keep it if he wanted or not.

One of my friend's father had one on his vehicle, which I just this minute realized was a big K5 Blazer. Green with a white fiberglass top.

When we were in our camp in the river swamp, hardly a day went by that we did not hear him on the radio asking for a winch-out.

That Warn would get him out of the slick stuff, but if he bogged it, he had to holler for help.

I watched him try one time while I was standing by with my Jeep and its PTO winch.
He hooked it up, turned on the winch.
That big anti-reverse wheel went Clickity, Clickity, Click..Click......Click...............Click.....and then a loud HUMM.

I winched him out.

The newer Warns are much improved now of course. I suspect that there are not many of the first ones left.

If they did not get thrown away, sooner or later someone would hook two batteries in parallel to try to get it to pull harder, and most times the gear box would fail.

You folks don't realize how nice things are now.
 
Well that's a different story to the typical "Best winch ever made" story I've continously heard.

Too bad I'll probably never use the thing. I'm a bit jaded with this whole project since they recently closed the local trail I was building this thing for. Hence the mall crawler description :)
 
I decided to put together a remote switch in addition to my in-cab setup. I used the same radio shack switches and hooked them up using trailer wiring connections. Here are some pics:

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Looks really good.

As for the brown wires, given their size, the only thing they could be is a thermal switch.
You would wire them in series with the power input for the coils of the solenoids. That way, if the motor overheated, it would kill power to the coils and thus kill power to the winch.

As long as you don't hold power on while its stalled, and don't do super long winch pulls without checking on the motor temp, you should be ok.

If the motor starts to smoke, stop.

To an old timer like me, its really funny to see folks bragging on and looking for those winches.

When they first came out, they were widely regarded as junk.
Around these parts at least.

My friend who built winches had a pile of them behind his shop that he had taken off to put one of his own.

At first, he gave a little trade-value for them, thinking he could make a good winch out of them.
They were so much prettier and nicer looking than his. But every attempt to make them pull to his level failed.

The last attempt, was to adapt a Ford 6V starter motor to them like we used for our winches.

Got it adapted, mounted the winch on the test bed, hooked up the big bus battery and fired her up.

It was looking good for a few seconds. Just when he thought he had a working idea, the gear box exploded!
After that, if someone wanted to do a trade, his only concession was to take the old one off for free.

The customer could keep it if he wanted or not.

One of my friend's father had one on his vehicle, which I just this minute realized was a big K5 Blazer. Green with a white fiberglass top.

When we were in our camp in the river swamp, hardly a day went by that we did not hear him on the radio asking for a winch-out.

That Warn would get him out of the slick stuff, but if he bogged it, he had to holler for help.

I watched him try one time while I was standing by with my Jeep and its PTO winch.
He hooked it up, turned on the winch.
That big anti-reverse wheel went Clickity, Clickity, Click..Click......Click...............Click.....and then a loud HUMM.

I winched him out.

The newer Warns are much improved now of course. I suspect that there are not many of the first ones left.

If they did not get thrown away, sooner or later someone would hook two batteries in parallel to try to get it to pull harder, and most times the gear box would fail.

You folks don't realize how nice things are now.

Haha, personal experience I guess.

Nothing against the newer Warn stuff, they are lighter and smaller than the old 8274 type stuff.

But a new 8K Warn won't hold a candle to an 8274. I promise I've dealt with MANY, MANY different winches. The off brand, import ones rarely even work in the first place and if they do, not for long IME. Warn's are the ticket IMO and the smaller, lighter new ones have their place for sure. Many vehicles can't easily fit the big 8274.

But if someone offered to trade a newer 9.5 X.. Warn for my 30 year old 8274 I would turn it down, unless I were to sell that one and buy another 8274 :deal:

Come wheeling with me sometime where a winch is needed, it'll change your mind ;)
 
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