Next I installed the three nylon drum bushings. I was surprized they weren't bronze, but I guess nylon reduces carnage. These sub 1k winches aren't that "high quality" anyway. :devil1:

The motor side drum bushings get lubed from oil splash, the other side is lubed from a zerk fitting in the very end (see the hole where the grease comes out).

Now I will be switching from captions above the pictures to captions below. :grin:

The highest speed bearing at the motor is lubed and sealed, the second highest uses nice ball bearings, the second highest uses roller bearings, and the slowest uses those bushings.

That large gear is the main drum gear. The small gear on the dual gear thing I'm holding drives the drum gear. You know how gears work...look at the picture.

When I was installing the 1st reduction stage I didn't use one of the "parts". I'm lucky I could get the little bearing back out so easily! I was wondering why there was .25" of .5" gas pipe nicely cut in the box. A closer look at the parts diagram and parts list shows a bushing/spacer. Without the little piece of gas pipe in the hole the gears wouldn't engage correctly.

 

So here is the brake side of the "box". The motor shaft drives the large gear on the top. The small gear right next to that big one has a little shift fork on it. This is the "engage" lever. Its just like in transfer cases.

When its shoved all the way into the other gear it will drive the large middle one, and the small middle one then drives the big drum gear.

This is what it looks like with the motor engaged.

So I'm ready to put them together...

The motor hole...

 

Motor hole with the sealed bearing.

Here is a motor slow down in reverse thing pinned to the end shaft of the motor. Thats what is in the funny looking cap on these motors.

I'm testing the winch with my battery tester. The case hasn't even been bolted together yet.

At first nothing happened, but then the winch started moving and got faster and faster. Then some smoke came out, but it kept on going. These motors are 30 years old and in very very poor shape. So I attempt to make one good one...

Here is all the motor junk that came with the winch.

One motor didn't turn, but it let out a few sparks. When I opened it up (which isn't as easy as it sounds due to the motor slow down chunk) I found winding insulation in there, but not on the windings anymore.

Then I pulled out the brush assembley. It was discolored and warped. Heat probably had a lot to do with this.

 

The best looking motor had very poor brushes. Some of them didn't even slide in their holders anymore. Basically all 3 motors were junk except for the armatures (the middle spinning thing), and even with those there was 1 good one and two marginal ones.

So I got out a brand new 8000lb Ramsey Winch replacement motor. It looks very similar, except for the armature, front and rear caps. The old moldy motor is on top and the new motor with the back cover removed is on the bottom.

The casing IDs and casing length were the same, so I went for it. I had to remove two allignment pins from the new casing that the old warn didn't have.

The new ramsey motor armature is in the middle, the best warn is on the top, and the worst warn is bottom. I think the bottom one was mounted to the winch when it was turned upside down, because its got oil allover it.

I shined up the commutator (the copper metal bars that the brushes rub on). The other two armatures had rusty gears or oil all over them.

 

The old armature fits pretty good. This is the back of the motor. The long end shaft is for that reverse brake.

Here is the new motor mounted on the winch. Not only is it new, but it is reversable and the stock one wasn't. So its basically a funny looking 8274 at this point.

And if it wasn't obvious, the winch works fine now. Except for one thing. The drum, or its shaft is out of round. Hopefully I can fix that. Running the winch as is it walks around.

Due to the reversable motor, I didn't put that reverse brake inside the cap on the end of the motor. That would have been counter productive.

I have one of these nice remotes from surpluscenter. It will make a good winch remote. I just have to change "Up" and "Down" to in and out.

Wish me luck on straightening this drum shaft!!!

 

As of yesterday I straightened the shaft to within .005" at 6". Its going to flex in the nylon bushings more than that, so I don't care.

Once its put together for the last time I'll post more pictures.

 

man, thats some crazy tech, how's your CNC cutter working?

 

Very nice. I haven't used it very much after making those rims. I do a little bit of brackets and that's about it. I didn't make it to actually make things, I did it because a local shop was having trouble making a 6" ring with holes. I knew I could do better, so I did.

 

Now that is some good tech.

Eric (Raven) has one of those winches sitting in his garage. Maybe he should make some of the modifications you have.

 

Ya, great tech dude. That is the same winch I have been running for a very long time. It came on a 73 CJ-6 that my Dad bought around 1977. Even have the same cable controls. Rebuilt the motor about ten years ago, and changed it to solenoids rather than the big cable actuated switch that it had.

 

I have read that you can use Ford starter solenoids to use with these winches. Which year and vehicle do I need to ask for?

 

thanks logjam for the great info and pictures I have a similar winch warn8200 that im in the process of cleaning up

 

i wouldn't use the ford starter solenoids they don't have a continuous duty cycle go with a warn solenoid they have a 100% duty cycle i saw a friends winch with the ford solenoids lock up and it wouldn't stop pulling because of the solenoids and broke his winch rope it could have been a serious situation but everyone got lucky

 

go with a warn solenoid they have a 100% duty cycle

And only rated for 100A.

 

Wish me luck on straightening this drum shaft!!!

Good Luck!

I live ~1 Mile from the MN 4wheeldrive center. They a brand new Bellview on display, well brand new as in never used but build a long time ago. I see if I can find the pics..

 

Cool, I just started my Belleview rebuild today and my motor won't spin. Curious why you didn't try to get one of your 3 to work?

 

ttt good article

 

Never had a winch before but just bought a Belleview tonight

It seems to be in great shape considering the age. I am concerned tht I cannot winch out. Is this normal on these winches. I notices someone else could not free spool out. This one does. I was also curious if I should be alarmed with the brake not working well at all. What is the brake for?

Thanks for your advice,

Sean

 

It seems to be in great shape considering the age. I am concerned tht I cannot winch out. Is this normal on these winches. I notices someone else could not free spool out. This one does. I was also curious if I should be alarmed with the brake not working well at all. What is the brake for?

Thanks for your advice,

Sean

your winch motor is a 1 way motor power in only,

the band brake holds the load when the motor is not powered,

 

Great Article. I have had 4 of these winches over the years, and have never had one fail. Not saying they wouldnt, just been lucky with mine. Dead reliable, extemely good priced used, and the overseas aftermarket for these winches is crazy! the one below I picked up for $250 and added the Rockstomper Winch Line. Still working great as far as I know(sold jeep). But just bought another to mount on the Pinzgauer!

 

Great Article.

Did you read it and look at the pictures?

the one below I picked up for $250 and added the Rockstomper Winch Line. Still working great as far as I know(sold jeep). But just bought another to mount on the Pinzgauer!

Looks like an 8274 on the front of that jeep....

 

wonder if the twin motor conversion for the 8724 will work on the belview

 

it wont work the twin motor conversion replaces the top half of the 8274 case, the belleview case is different

 

I know this is an old old thread, but I just recently pick up an old bellview/warn winch for really cheap . Needs a motor and solenoid pack.

But my question is I cannot really figure out what the winch is . The part ID numbers on top are 5967
7149


EJ4.

Thats how its laid out on the top of the winch. Those part numbers don't seem to match the bellview so I am now not sure which one it is.
Any help would be great.

 

Sure it doesn't say 5687? If so, it's an old Warn. Middle step between the Belleview and 8274

 

Cool thread. I have a Belleview 6000 on a reciever hitch. I put 125' of 3/8s synthetic winch line on it and wired it with solenoids. Its a great winch! Very fast, pulls hard.

 

Cool, well I found out after some more digging around , that the winch i have is a warn 8200 the one just before the 8274. So not a bellevue either.

 

I want an 8200 . . .drool

 

I hate to be dragging this thread back up again, but, in the middle of working up my mod plans for this spring my front winch and this thread came to my head.
If I fry up the motor on my 8200, am I going to be stuck building a new motor like the OP had to do with the Belleview, or can I bolt on an 8274 motor and go? Maybe one of the current motors?
I'd pull mine apart and examine it, but, it's Saturday night, I'm having silly ideas, and the nose of my wheeling pig is under about 4 feet of snow right now.... LOL

On a related note, a friend of mine has a Belleview that he dispises because of the brake on it. Can an 8200/8274 style brake be retrofitted to it?
He's planning on demoting it to trailer winch status and just running a cheapie 8500 Superwinch on the front of his truck. If we can upgrade the brake, we'll probably add a 2 way motor to the thing too.
I'd be making off with it for my own use, but, I have a circa 1984 M12000 in pieces I've had kicking around for years I need to get around to putting into service on the rear of my junk...