Picked up an older (pre 2000) Warn XD9000i for my Bronco and figured I would share the results of my restoration efforts. It was in pretty good shape to start with, so I didn't have to do much. Blast, paint, rewire, regrease, assemble!
As I bought it:
The internals were in remarkably good shape with minimal corrosion. I ended up sandblasting everything and repainting with a decent VHT epoxy in a spray can. It's not a true 2 part epoxy paint, but it's good stuff. I used aluminum-specific primer on all the aluminum parts, then a standard self-etching primer on all the steel parts.
I also sprayed the motor parts with a 2800V insulating varnish to help prevent any future motor failure. Brushes were in great shape and didn't need any maintenance.
Warn has drastically increased the price of their replacement parts, especially on small items such as gaskets. I wasn't willing to fork over nearly $40 for a set of gaskets, so I measured and lasered my own.
I then reassembled and regreased with Aeroshell 64.
The control box was in good shape, overall, but did have some minor corrosion starting. I scotch brited all contact surfaces, treated with deoxit (amazing stuff, well worth the cost), then coated the busbars and lugs with a very special conductive and corrosion preventing grease. The cables themselves were in pretty good shape and I didn't feel like they needed replacement.
I made new main battery cables from 2 gauge welding cable to finish off the project, putting a 300A manually resettable circuit breaker in line with the positive. I wanted to go with larger cable, but it wouldn't fit the grommet in the control box.
These are an absolutely wonderful tool to have for working with anything from 8 gauge to 1/0 cable.
A good hydraulic crimper is a fantastic tool to have around, and they really aren't that expensive. Mine is a TEMCo and can do 10 gauge to 600 MCM.
And here's the final result. I found the bumper on FB marketplace for about half the price of the weld it kit I had been looking at and it's actually the exact same bumper. The welding is fine, but the bedliner sucks. Next time I pull the bumper, I'll strip and have it powder coated, plus a few mods.
Overall, pretty happy with how it turned out!
As I bought it:
The internals were in remarkably good shape with minimal corrosion. I ended up sandblasting everything and repainting with a decent VHT epoxy in a spray can. It's not a true 2 part epoxy paint, but it's good stuff. I used aluminum-specific primer on all the aluminum parts, then a standard self-etching primer on all the steel parts.
I also sprayed the motor parts with a 2800V insulating varnish to help prevent any future motor failure. Brushes were in great shape and didn't need any maintenance.
Warn has drastically increased the price of their replacement parts, especially on small items such as gaskets. I wasn't willing to fork over nearly $40 for a set of gaskets, so I measured and lasered my own.
I then reassembled and regreased with Aeroshell 64.
The control box was in good shape, overall, but did have some minor corrosion starting. I scotch brited all contact surfaces, treated with deoxit (amazing stuff, well worth the cost), then coated the busbars and lugs with a very special conductive and corrosion preventing grease. The cables themselves were in pretty good shape and I didn't feel like they needed replacement.
I made new main battery cables from 2 gauge welding cable to finish off the project, putting a 300A manually resettable circuit breaker in line with the positive. I wanted to go with larger cable, but it wouldn't fit the grommet in the control box.
These are an absolutely wonderful tool to have for working with anything from 8 gauge to 1/0 cable.
A good hydraulic crimper is a fantastic tool to have around, and they really aren't that expensive. Mine is a TEMCo and can do 10 gauge to 600 MCM.
And here's the final result. I found the bumper on FB marketplace for about half the price of the weld it kit I had been looking at and it's actually the exact same bumper. The welding is fine, but the bedliner sucks. Next time I pull the bumper, I'll strip and have it powder coated, plus a few mods.
Overall, pretty happy with how it turned out!
