SteveG Posted December 4, 2007 Share Posted December 4, 2007 I've had the EP9 for about 15 months now. I first stripped it to service it after six months and at that time I replaced the very thick black grease it shipped with, with some normal multi-purpose grease. As it was now 9 months on I'd thought I'd strip it again at the weekend, as it's had quite a few dunkings in that time. I also wanted to change the grease to CV grease as this had been recommended by Nick Watts (RogueVogue) and Paul Wightman when I asked. I thought this may make freespooling easier as Bish was bitching when performing winch monkey duties at 7 Sisters I took some pics, just in case they were useful to anyone. Not having read the manual , you'll find me using my own naming scheme for the parts It's very easy to take apart an EP9. You start but undoing the two drum rods. Once undone you can pull apart the motor housing, gear/brake housing and the drum. Here's the gear/brake housing, also showing the motor drive rod that runs through the centre of the drum.. The motor housing, showing the motor gear adapter to the drive rod.. Motor end of drum.. Gearbox end of drum (Highly exciting stuff isn't it! ).. I appear to have been lucky again and no water or mud has passed the nylon bush on the motor end... Not so lucky on the gearbox side , but frankly I was expecting this. You can see the muddy grease already.. To release the gearbox end plate, you first turn over and undo the brake cover. Simply undo the 3 allen screws.. You can now see the brake cam on the end of the housing, the enclosure that activates the cam and the brake cover. The Hylomar, I used after the first strip down, seems to have kept water out and the surface rust you see on the cone brake was there on first strip down too... You then undo six more allen screws that are exposed now that the brake cover is off. You can then turn over and reveal all the messy grease/mud .. You can then take off the Nylon washer and lift the main planetary gear set out (upper part of pick). Often when you lift this main gear set out out comes the first of the smaller planetary gear sets. You can see the second of the smaller gear sets still in the housing. You can't get these mixed up as each has a different length output shaft.. You then need to split the housing in two to remove the outer ring gear. For me, a short tap with a cold chisel does the trick.. This exposes another nylon washer and the inner ring gear that is part of the freespool mechanism. On pulling this out I noticed that water has been getting in via the freespool lever and obviously some corrosion has developed when the winch has been stationary. This build up can stop the freespool gear from moving freely. I think the only solution here is to silicon seal up the outer part of the freespool lever where it meets the housing... There seemed no need to take apart the brake mechanism and especially as I didn't have any new circlips I wasn't going too just for pics! I cleaned off the rust on the housing and the freespool ring gear. I also cleaned off the gunk in all the gear sets and on the nylon washers... This time the gaskets between the parts of the housing and between the housing and the end plate had perished too much, so I removed them and used hylomar to seal up on reassembly. Then it's simply a case of greasing everything again and putting back together in reverse order. I used LR one shot CV grease.. Finally I sanded down the rusty drum bars and gave them a couple of coats of silver paint for nothing more than aesthetic reasons Thanks to Dave, Landrover598 for the idea. They go so well with the chipping powder coat. As there was no water ingress, I didn't strip down the motor so you don't get any pics of this . Cheers Steve Quote Link to comment Share on other sites More sharing options...
JST Posted December 4, 2007 Share Posted December 4, 2007 good article, can you do one on a husky and 8274 now please Quote Link to comment Share on other sites More sharing options...
SteveG Posted December 4, 2007 Author Share Posted December 4, 2007 good article, can you do one on a husky and 8274 now please 8274 is even easier.. Alas, I don't have one to hand to do a write up, unless someone wants to post one over Quote Link to comment Share on other sites More sharing options...
v8bertha Posted December 4, 2007 Share Posted December 4, 2007 good article, can you do one on a husky and 8274 now please Excellent! Just what I needed as the Come-up DV9000 (basically the same as an EP9, but gray instead of black) on the front of Bertha needs a bit of TLC. Where can you get spare parts from if needed? D :-) Quote Link to comment Share on other sites More sharing options...
SteveG Posted December 4, 2007 Author Share Posted December 4, 2007 Where can you get spare parts from if needed?D :-) Phil at PG Winches can supply all superwinch and come-up spares. Winch Repairs Cheers Steve Quote Link to comment Share on other sites More sharing options...
BogMonster Posted December 4, 2007 Share Posted December 4, 2007 One for the tech archive I think Modesty forbids me from pointing out that if you bought a Milemarker you wouldn't have to pull it to bits ever Quote Link to comment Share on other sites More sharing options...
suggs Posted December 4, 2007 Share Posted December 4, 2007 handy tips there mate.. Quote Link to comment Share on other sites More sharing options...
smo Posted December 4, 2007 Share Posted December 4, 2007 So which bits need packing with grease, and which bits need "silicone" sealing to keep the water out? Quote Link to comment Share on other sites More sharing options...
TJ101 Posted December 4, 2007 Share Posted December 4, 2007 8274 is even easier.. Think i recognize that one Steve Quote Link to comment Share on other sites More sharing options...
SteveG Posted December 4, 2007 Author Share Posted December 4, 2007 Think i recognize that one Steve Not your one Tim, that was one I brought back from US that Les B now has. Yours just had a couple of brake strip downs and general clean up and re-oil, oh and a new motor. I take it it's still running strong? So which bits need packing with grease, and which bits need "silicone" sealing to keep the water out? Not so much packing. I fed grease into brake housing, freespool ring gear, all gear sets and nylon washers. Both nylon bushes on end plates got a covering of grease along with their respective end bushes on the drum. I also put a touch of grease on the bearing on the clutch mechanism that mates with the brake cover. Hylomar used for sealing all sealed mating surfaces on gear/brake housing and it's end plate. I've left the standard rubber gaskets on the motor alone as they appear to be working ok. As for silicon, just going to use around the freespool mechanism where it joins with the outside of the gear/brake housing. As for trying to make it waterproof the housing joind and the housing to end plates seal ok, it's the point that they mate with the drum that's the issue. I would think that if you replace the nylon bushes with a proper bearing oil seal and breathers to the housing you could make it a lot better than it is. The nylon bushes are not a full circle and are C shapped and line up with a small notch on the housing to stop it rotating. So you'd have to find a suitable bearing seal and work out how to fit in a fashion similar to the 8274 drum seal. Cheers Steve Quote Link to comment Share on other sites More sharing options...
TJ101 Posted December 4, 2007 Share Posted December 4, 2007 Not your one Tim, that was one I brought back from US that Les B now has. Yours just had a couple of brake strip downs and general clean up and re-oil, oh and a new motor. I take it it's still running strong? Steve Yep, still going strong,, nothing another new motor, brake rebuild, and re oil has not cured !! Quote Link to comment Share on other sites More sharing options...
tcmault Posted August 9, 2012 Share Posted August 9, 2012 I know this is dusting off an old thread, but do you remember it seeming odd that there were only 6 bolts in the gear retaining ring when there are nine holes? Do the three that hold on the end cap go all the way through to the support? I tore mine down and just don't remember removing nine bolts from the brake assembly and only have 6 of the black allen head bolts and 3 stainless allend head bolts that are longer. Quote Link to comment Share on other sites More sharing options...
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