Anyone rebuild a Warn Zeon 10s?

Mike Pierson

Mike Pierson

Hooked
Was out wheeling in shitty snow around Mt Shasta on Saturday and we winched a ton! I use this bad boy a lot in the winter as you could imagine. On one heavy pull I was trying to pull back a stuck JK and the passenger side of the winch slipped about a half inch, coming in hard contact with the frame end plate. Enough that it dented the winch housing a bit. I have the EVO quarter pounder and it’s a bear to get the passengers side tight enough, and apparently I didn’t. Right after that the winch sounded like the teeth are sheered inside. It still “works” but it sounds pretty bad when spooling in and out.

I called WARN and set up an RMA for a warranty check and repair but it’s entirely possible that they won’t warranty it and I’ll be on the hook to have them repair it. Sounds like the cost would be around $200+ not including the cost of shipping up to Oregon.

So, has anyone been able to repair theirs successfully?

Thanks!
 
Took it apart. Motor looks good, smells fine, like it’s not burnt. The teeth on all the gears look great. The two planetary sets seem very loose in their housing though, and that may account for the grinding noise I hear. One thing I noticed was there really wasn’t that much grease in there, not as much as I’d expect to see at least.

Also, one of the stainless steel screws holding the gear-set cover on broke right at the housing. I was only using a screwdriver too. 😡 Fuuuuuuuu

Will give WARN a call again tomorrow. 🤷🏼‍♂️
 
Mike Pierson said:
Took it apart. Motor looks good, smells fine, like it’s not burnt. The teeth on all the gears look great. The two planetary sets seem very loose in their housing though, and that may account for the grinding noise I hear. One thing I noticed was there really wasn’t that much grease in there, not as much as I’d expect to see at least.

Also, one of the stainless steel screws holding the gear-set cover on broke right at the housing. I was only using a screwdriver too. 😡 Fuuuuuuuu

Will give WARN a call again tomorrow. 🤷🏼‍♂️
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There is a very specific grease that you should be using on your winch gears. Ask WARN about it when you call them up.

If I recall, it might be this
 
So had my call with WARN, very good support I might add… My concerns about, loose planetary gears and what I perceived to be too little grease, is all normal. So I guess I’m going to send it in anyway and at least it’ll get a refresh inside.

I’m very happy with this winch, going on five years old and I’ve used it a bunch every year. My guess is that had it not slipped in the bumper, and hit the frame, it would still be working like new. 👍🏻

On reinstall I’ll be either removing the sway bar for easier access or using a hole saw to drill a large hole on each underside of the bumper; haven’t decided yet.
 
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