My warn 9.5xp-s stopped working recently and it's only a few years old. I thought at first it was something simple like a loose wire....it wasn't. We tested the solenoid and completely tore it apart (had to use a soldering iron), cleaned all the contacts and reassembled it. We tested the winch and it seemed to be working so we reinstalled everything. As we were winding in the rope, same issue. Solenoid clicks but no motor movement. I put the winch in free spool mode, turned the drum manually and tried again...motor turns again. Ok, it must be the brushes. We removed the winch from the truck again...ugggghhh...took the motor apart and what did we find? 3 out of 4 brushes were seized and not making contact. The cause of the seizing was corrosion. We freed up all the moving parts and reassembled it. The route cause? There are two drain canals on the motor to winch assembly gasket surface. The one pointing downward should be OPEN and the one pointing up or side must be CLOSED with silicone. Whoever installed it screwed up and filled the wrong one. 7 hours later, my winch works again.
Inspect your winch drain canal
- Thread starter dahorst
- Start date
