Koenig King Winch

[HO455]

I picked this little winch up a couple weeks ago and thought I'd go through it here. It came complete a with bumper and some drive line. It looked as if it had been used but not really abused and not left out to rot behind a garage. I'm hoping the inside looks like the outside. It wasn't frozen up and everything seem to work so that's a good sign. Right?

[HO455]

I did break 2 of the bolts off getting it off of the bumper, but the rest of it came apart without any issues. There was a small amount of corrosion inside, which was expected but nothing too depressing as the worst was on the worm gear bearings.
The winch has been apart before as there is some previous gauling on the worm gear shaft. It doesn't seem to be terrible but after clean up I'll know more. The important thing is the gear set looks to be in great shape.
The broken mounting bolts resisted my intial efforts to remove them so I'll soak them and try again later.

[HO455]

Here are more photos of the winch as it came apart. Hopefully when cleaning I won't find any hidden issues, but as of now things look good.
I did some searching for parts on the interweb and found a guy with a web site called Herm the Overdrive Guy. After looking around the site and then some Jeep sites for reviews on Herm I decided to contact him about some parts. That's when I saw he was just across the river in Washington so I called him and set up a time go meet and him on Labor Day.
Herm and his 2 employees were hard at working to package and ship parts out. Herm said they are super busy and running flat out to keep up with demand. I took the shafts with me and he agreed they weren't a problem so I got a gasket set, imput shaft seal, worm gear bearings, and a new brake pad and headed back home. Herm gave me some tips on reassembly and we talked cars for a bit before I left. Real nice folks with nice business supplying mostly early Jeep running gear parts.

http://hermtheoverdriveguy.com

[mongocanfly]

That's a nicun..!!!

[Ol Blue K20]

I'm in to watch.

[HO455]

I hope to get more done next week. With work and the fires here there's been no opportunity to get anything done.

[HO455]

I got a couple of hours of cleaning on the winch and another hour and a half removing the two mounting bolts that twisted off when I removed the winch from the bumper. I soaked the two housings for a week or so in penetrating oil in preparation for the battle to remove the bolts and not screw up the aluminium housings.

To get them out I clamped the housing down and then heated it with a Mapp torch to about 150*. Then I would spray some penetrating oil on the threads on both end of the bolt to cool and then to shock the corrosion around the bolt I tapped the bolt with a hammer, more oil to flush debris. Then grab the remaining piece of the bolt with a pair of Vice Grips and wiggle back and forth trying to get the bolt to break free. I repeated the process over and over until eventually the bolt would start to wiggle and then spraying more oil on the threads to wash more debris out and slowly the bolts came out without gauling the threads.

One bolt fought much harder to stay in and the remaining piece was getting small and pointed. I then had to take a grinder and carefully make two flat spots to be able to get a solid grip on the bolt. The first bolt took about 20 minutes to remove and the second one about 90 minutes to get free.

I suppose I could have drilled them out and tapped them for the next size up ,but then my ADD would have made me do the same on the other 6 holes so they would all be the same.

[Ol Blue K20]

It's a great feeling you conquer something. Congratulations on the win!

[HO455]

Thank you old Blue!
I cleaned up the dog engagement/brake lever assembly. (Photo 1)The hand lever moves the dogs in and out allowing the drum to freewheel or be driven. The same lever also applies the brake.
The lock out pin was in poor shape, the roll pin that spring loads the pin was rusted and the ends were missing. In addition the end of the pin had been cut or broken off. (Photo 2)
Fortunately there was just enough length so I could drill a new hole in the pin for a new roll pin (Photo 3) and then bevel the end of the lock pin.
The lock out pin assembly consists of the pin, a bushing that holds the assembly in place, a spring, a washer, and the roll pin. (Photo 4)
The last photo shows the assembled pin.

[HO455]

The pin assembly is inserted into the lever base and a set screw holds it in place. The pin bushing has a groove in the OD (Green arrow in previous photo) that the set screw contacts to lock it down.
The pivot for the engagement lever was very rusty so I made a new one from a piece of rod I had.
Looking back at these 2 posts it is apparent that painting all of the parts black doesn't produce the best picture clarity. I will try to avoid that in the future.

[Ol Blue K20]

It looks like you're on a roll and making progress. Keep it up!