WINCH UNIT REASSEMBLY


  1. INSTALL WINCH MOTOR BRUSH SPRING


    1. A015ALA

      Install the brush spring as shown in the illustration.

  2. INSTALL NO. 1 WINCH MOTOR ARMATURE BEARING


    1. A015DLXE01

      Using a 12 mm socket wrench and press, press in a new bearing.

  3. INSTALL NO. 2 WINCH MOTOR ARMATURE BEARING


    1. A0158BXE01

      Using a 19 mm socket wrench and press, press in a new bearing.

  4. INSTALL WINCH MOTOR ARMATURE SUB-ASSEMBLY


    1. A015DDU

      Apply high temperature grease to the inside of the end frame bushing.

    2. Install the armature to the end frame.

  5. INSTALL WINCH MOTOR YOKE SUB-ASSEMBLY


    1. A0157NS

      Align the alignment marks and install the yoke to the end frame.

  6. INSTALL WINCH MOTOR BRUSH HOLDER ASSEMBLY


    1. A0156LO

      Align the alignment marks and install the brush holder to the yoke.

  7. INSTALL WINCH MOTOR BRUSH


    1. A015613

      Install the brush with the bolt.

      Torque:
      3.4 N*m  { 35 kgf*cm, 30 in.*lbf }
    2. A0155GS

      Using a screwdriver, pry the brush spring forward and insert the brush into the holder as shown in the illustration, then remove the screwdriver from the spring.

      Tech Tips

      Use the same procedures to install the 3 remaining brushes.

  8. INSTALL WINCH MOTOR O-RING


    1. Install a new O-ring to the yoke.

  9. INSTALL WINCH MOTOR COMMUTATOR END FRAME


    1. A015D01

      Install the end frame with the 2 bolts.

      Torque:
      7.7 N*m  { 79 kgf*cm, 69 in.*lbf }

  10. INSTALL WINCH MOTOR MAGNET SWITCH ASSEMBLY


    1. A0157TQ

      Install the switch to the motor with the 4 bolts.

      Torque:
      4.9 N*m  { 50 kgf*cm, 43 in.*lbf }
    2. A015DT4

      Install the wire harness with the 2 washers, 2 spring washers and 2 nuts.

      Torque:
      9.3 N*m  { 95 kgf*cm, 82 in.*lbf }

    3. Connect the connector.

  11. INSTALL MAGNET SWITCH WINCH COVER


    1. A015BUS

      Install the cover with the 4 screws.

      Torque:
      1.5 N*m  { 15 kgf*cm, 13 in.*lbf }

  12. INSTALL WINCH ROLLER BRACKET ASSEMBLY


    1. A015ARYE01

      Install the roller bracket with the 4 bolts and 2 nuts.

      Torque:
      for bolt A
      21.6 N*m  { 220 kgf*cm, 15 ft.*lbf }
      for bolt B
      28.4 N*m  { 289 kgf*cm, 20 ft.*lbf }

  13. INSTALL NO. 2 WINCH EARTH WIRE


    1. A015DG6

      Install the winch earth wire with the bolt.

      Torque:
      17.5 N*m  { 178 kgf*cm, 12 ft.*lbf }

  14. INSTALL WINCH MOTOR ASSEMBLY

    A0159YA

    1. Install the winch motor with the 3 bolts.

      Torque:
      15.7 N*m  { 160 kgf*cm, 11 ft.*lbf }
    2. A0158NEE01

      Install the winch base with the 8 bolts.

      Torque:
      for bolt A
      32.3 N*m  { 329 kgf*cm, 23 ft.*lbf }
      for bolt B
      58.8 N*m  { 599 kgf*cm, 43 ft.*lbf }
    3. A015DW9

      Install the member with the 4 bolts.

      Torque:
      21.6 N*m  { 220 kgf*cm, 15 ft.*lbf }