Warn 9.5ti Restoration DONE!
I'm not sure I've ever been happier to be done with a project. This took me about 7 weeks working occasionally. I made a number of mistakes, and took several steps backward on a number of occasions. 1- I screwed up the original motor somehow. I think when I was cleaning it up, I removed some insulation which prevents the coils from generating a magnetic field. I'll have to track it down, but I ended up buying a new motor from Warn for $225 or so. 2 - Assembly took a few tries because this 9.5ti is an old model and the small sun gear is retained by a clip. As such, assembly has to be done with the main shaft already through the drum. I didn't know that and had to do the assembly over once I realized this. 3 - Once everything was installed and wired, I found the small wiring harness connectors were totally corroded. This is common if the protective cap is broken off. They just crumbled so I had to order a new harness for about $75. 4 - Brake assembly - Warn customer service was really great. I emailed them a few times with pictures as I wanted some guidance on pre-load for the brake. Quick response and they emailed me some diagrams not normally included in manuals. I did not include video of my trying to get the original motor running. I have them, and can load them to show how to re-assemble the motor. But in my case, it doesn't work. If you're interested, just post a comment below. I appreciate any comments and suggestions. Yes, even the ones that compare my voice to Ben Stein :) Thanks for watching!

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