Warn 9500ti break down... parts/replacement needed!? - Pirate4x4.Com : 4x4 and Off-Road Forum
 
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Old 04-04-2010, 06:44 PM   #1 (permalink)
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Warn 9500ti break down... parts/replacement needed!?

I decided to break open my Warn 9500ti that decided to stop working last fall. I bought it used a few years ago and up until the end, it's been strong and reliable. During the tear down I found a large allen head bolt broken and snapped two little ones off in my efforts to disassemble it. The large one was twisted off inside the control assembly cover and during my attempts to remove THAT, it broke as well.
Once it was all apart, I tested the solenoids to find them operating well, I pulled the end off the motor to see how that looked and found a lot of rust, corrosion and aluminum salt. Motor looks to be pretty well thrashed internally. Probably rebuild-able but at what cost?

Anybody know what price I'm looking at for these parts?
1- PN 64635 Motor
2- PN 5553 #10-24 socket head screws
1- PN 64637 Cover- Control assembly
1- PN 64634 Drum Support -Motor
3- PN 64405 5/16x18 Screws
2- PN 13848 Housing gasket
1- PN 64642 Seal Kit
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Old 04-04-2010, 07:10 PM   #2 (permalink)
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Quote:
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Anybody know what price I'm looking at for these parts?
1- PN 64635 Motor 247.13
2- PN 5553 #10-24 socket head screws $0.96/ea
1- PN 64637 Cover- Control assembly $67.09
1- PN 64634 Drum Support -Motor $89.46
3- PN 64405 5/16x18 Screws $2.66
2- PN 13848 Housing gasket $0.96
1- PN 64642 Seal Kit $26.35

http://www.warn.com/store/service_parts.jsp
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Old 04-04-2010, 08:37 PM   #3 (permalink)
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So direct from Warn it's going to run me 479.20 including shipping. Plus some more labor and grease to get this sombitch back up and running....
Obviously worth it when compared to buying a new one but the budget is not going to like that hit. Any one know a friendly dealer? or someone have a spare motor sitting around?.... maybe?
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Old 04-04-2010, 09:01 PM   #4 (permalink)
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Go to alternator or starter rebuild shop they should have the motor in stock and or repair your existing motor.
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Old 04-05-2010, 04:27 AM   #5 (permalink)
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I have a 9500i & it stopped working also. I did some research & the 9500i have a tendacy to loose ground at the motor. You have to put 2 little washers between the motor. So you put the long bolts through the cap & slide the 2 washers on the bolts under the cap.then though the motor & tighten. That puts extra pressure on the motor so it doesn't loose ground. I would clean the motor & try it. Otherwise you can put a aftermarket motor on for around $150. This is who helped me at Warn 1-800-522 9276 ext. 3205 Augie I think thats his name. Good Luck
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Old 04-06-2010, 07:17 PM   #6 (permalink)
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after looking over the motor and scraping off some of the corruption, filth and corrosion, I found a few things going on... the screws connecting the brush wires were pretty well fried, the ground is suspect and the little temperature dongle is rotted all to hell. I'm guessing the local starter/alternator guy can remedy everything but the dongle. Anyone know what I'm talking about and maybe where to find one?
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Old 04-09-2010, 03:04 PM   #7 (permalink)
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took the motor to my local shop, a guy I've dealt with quite a few times and has been able to get me up and running pretty cheap in the past. Unfortunately, the aftermarket is not competitive with Warn.
HIS cost for a new motor is $540 and there are no replacement parts available.
So that's route a no-go.
Now the question is, do I spend the $500 for parts plus the time cleaning, lubing, scraping, and painting to fix this thing back up and wonder when the solenoid pack is going to crap out or do i spend the 500 elsewhere and get a decent winch for the dozen or so times I'd use it every year?

Any decent 8-10k winches out there for under 600? Yep, I know they'll likely be foreign made, but I'd like to get an idea of what I'll be getting if I spend my money one way or the other.
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Old 04-09-2010, 03:52 PM   #8 (permalink)
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m8000 can be had for about $500

I found a brush head for an older 9500 on amazon... parts are available.
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Old 04-10-2010, 08:42 AM   #9 (permalink)
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Quote:
Originally Posted by Stonecoast View Post
took the motor to my local shop, a guy I've dealt with quite a few times and has been able to get me up and running pretty cheap in the past. Unfortunately, the aftermarket is not competitive with Warn.
HIS cost for a new motor is $540 and there are no replacement parts available.
So that's route a no-go.
Now the question is, do I spend the $500 for parts plus the time cleaning, lubing, scraping, and painting to fix this thing back up and wonder when the solenoid pack is going to crap out or do i spend the 500 elsewhere and get a decent winch for the dozen or so times I'd use it every year?

Any decent 8-10k winches out there for under 600? Yep, I know they'll likely be foreign made, but I'd like to get an idea of what I'll be getting if I spend my money one way or the other.
Was it an alternator/starter repair shop? The parts are out there and they are not that expensive. I bought a new motor for my M12000 (6hp) for $250 and I got a new armature and brushes for my existing motor which was all I needed so now I have a spare motor. The time is worth it...
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Old 04-10-2010, 11:07 AM   #10 (permalink)
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Was it an alternator/starter repair shop? The parts are out there and they are not that expensive. I bought a new motor for my M12000 (6hp) for $250 and I got a new armature and brushes for my existing motor which was all I needed so now I have a spare motor. The time is worth it...
Where'd you get the motor?
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Old 04-10-2010, 11:15 AM   #11 (permalink)
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I got it about 3-4 years ago before the 6HP upgrade was popular.

Here is the company I dealt with in person.

http://www.amperagetech.com/id33.htm

They are very knowledgeable.
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Old 04-10-2010, 09:46 PM   #12 (permalink)
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Looked there... nothing for 9500ti. It's an odd motor because there isn't a carrier bearing on the motor, it's in the housing and the shaft for the 9500ti is smaller as well.
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Old 04-11-2010, 02:59 PM   #13 (permalink)
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Call them on monday I am sure they will have what you need.
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Old 05-08-2010, 03:37 PM   #14 (permalink)
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Ran into an issue with my 9500ti. It won't power off. As soon as I touch the cables to the battery it'll start to spool in. The controller is not even connected. I did just replace the red and black cables. The black cable is going to the ground on the underside of the motor and the red is going to the far right solenoid if looking directly at the W. Closest to the control plug-in.

Any ideas?
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Old 05-09-2010, 08:37 AM   #15 (permalink)
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I'd bet dollars to donuts the positive lead you replaced is in contact with something it shouldn't be. Open it up and try again. The other option is a stuck solenoid which could be temporarily fixed by tapping it gently but sharply.
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Old 05-09-2010, 10:00 AM   #16 (permalink)
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Only 2 wires are connected to the back post of the far right solenoid. One is a white wire going to the controller plug and the other is the positive cable going to the battery. So it sounds like a stuck solenoid? I'll take the white wire off and see what happens.
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