Is there a blow-up of the pinion repair kit showing the correct way to install it?
asked by: Richard M
I can explain exactly how to install the pinion shaft repair kit, # F1563S01. You can refer to the picture I have included.
Start be removing the old parts. It is recommended to disengage the brake ahead of time. You can do this by placing your foot on the drum, applying pressure, and turn the handle in the cable out direction. This will loosen the parts.
Next, remove the nut on the end opposite of the handle. If there is an e-clip on the other end, you will need to remove it with a flat head screwdriver. Careful, they can fly off! With the e-clip off you should be able to pull the assembly out about half way.
Pull off the parts on the free end of the shaft and then pull the shaft all of the way out. If you find that the assembly will not come out there could be a thin washer that has fallen into the e-clip groove, if equipped.
With the old parts out you can install the new parts. Start by placing the larger bushings, part A in the picture, into the pinion shaft holes on either side of the winch. The larger diameter side faces the inside of the winch. There may be a notch in these bushings that fits into a slot in the pinion shaft hole.
Next, insert the shaft, part B, in the hole on the handle side.Only insert it about half way so you can slide the other parts on.
Next, slide on the thin washer if present. Then slide on the large washer, part C, followed by the brake pad material (retained from old parts). The large washer has an oblong shaped hole and it will fit a certain way to be fully seated. Make sure that it is fully seated.
Next slide on the large gear, part D, and the other brake pad disc. The last piece of this assembly to go on is the smaller gear, part E. The large flat washer end should face the brake disc. The inside of this gear is threaded and you can get it snug enough for now by holding the gear end with one hand and turning the pinion shaft with the other. Make sure that part C is still fully seated.
Next, push the shaft through the other hole on the winch body. Doing this can unseat the bushings, part A. Make sure they are seated properly before tightening everything. You can then slide bushing F from the outside of the winch in and around the pinion shaft. make sure everything is still seated properly.
Next place a nut, part G, on the non-handle side of the shaft if equipped. On the other side you can attach the handle. Then use a wrench to tighten the nut. Secure the handle with the remaining hardware.
During the installation, the paw that ratchets on the gear would come off. You can put it back in place by detaching the spring where it holds onto the winch body (do not remove the spring from the paw), rotate both units around, and re-secure the spring to the winch body. Small screwdrivers help to reach in there and push the paw and spring around.
If the winch had an e-clip, you can install it last by pushing it into its groove on the pinion shaft. These clips can be tough to get back on. I used a wrench and pushed it into place.
The last step is to re-set the brake. To do this, you can wedge the end of a screwdriver in the gears to prevent them from turning, and turn the handle in the cable in direction. You may need to stop and re-tighten the non-handle nut. I have included a link to an FAQ that explains re-setting the brake.
expert reply by: Michael H
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Winch Repair Kit
Featured Help InformationFulton Brake Winch-Brake Set