Electric Winch

REMOVAL

Remove the parts in the numerical order shown in the figure.

Fig. 10-35

Winch Rear Position

1. Negative Battery Terminal

2. Wiring Harness

3. Connector

5. Winch with Rear Base Member

6. Rear Base Member

Fig. 10-36

Fig. 10-36

DISASSEMBLY

1. Disassemble the winch in the numerical order shown in the figure.

Fig. 10-37

Land Cruiser Winch Lever

Housing Cover Cable

Winch Set Plate Winch Housing Drum Spacer Case Cover

Fig. 10-38

Fig. 10-38

Mosquito Cartoon Chikgungya

Remove the winch cable.

Fig. 10-39

Winch Cable Counter

Loosen each bolt a little at a time, and in the sequence shown in figure.

Disassemble the case cover in the numerical order shown in the figure.

Fig. 10-40

Land CruiserWinch Cable Counter

Fig. 10-44

Fig. 10-44

2. Input Shaft

3. Slotted Spring Pin

4. No.1 CounterShaft

5. Clutch

6. Clutch Outer Race

7. Thrust Bearing & Race

8. Snap Ring

9. One-way Clutch 10. No.1 Counter Gear

1 1. Clutch Outer Disc, Inner Disc & Plate

Fig. 10-41

Fig. 10-41

Fig. 10-42

0 Remove the slotted spring pin with a pin punch.

Fig. 10-42

Tap the case cover with a plastic hammer and remove the No.1 counter shaft.

Fig. 10-43

Fig. 10-43

Outer Rotating Winch Gearbox

If No.1 counter shaft is difficult to remove, lightly tap out the case cover with a plastic hammer while rotating the clutch subassembly by hand.

Fig. 10-44

Remove the snap ring.

Fig. 10-45

Remove No.1 counter gear.

Remove No.1 counter gear.

Disassemble the winch case in the numerical order shown in the figure.

Fig. 10-46

Fig. 10-46

Gear Shifter Slotted Shaft

1.

Winch Drum & Spacer

2.

Shift Lever

3

No.2 Counter Shaft

4

No.3 & No 4 Counter Geai

5

Free Spool

6

Cruiser Billet Shift Levers

Before removing the winch drum, shift the lever to the lock position.

Fig. 10-48

Fig. 10-49

Remove the winch drum.

Tap out No.2 counter shaft.

Fig. 10-50

Land Cruiser Shift Lever Removal

Be careful when removing the shift retainer as the steel ball may fly out.

Fig. 10-51

INSPECTION & REPAIR

Case Cover

Check for damage.

Fig. 10-52

Fig. 10-52

Check the slotted spring hole for bits of debris.

Fig. 10-53

Fig. 10-53

Check the slotted spring hole for bits of debris.

Thoroughly remove all debris from the hole as it will cause damage to the 0 ring.

Fig. 10-54

Fig. 10-54

Oil Seal

1. Check the lip for wear or damage

Fig. 10-55

Fig. 10-55

2. Replace the oil seal.

(1) Remove the oil seal.

2. Replace the oil seal.

(1) Remove the oil seal.

Fig. 10-56

Fig. 10-56

Toyota Landcruiser Restorer

(2) Install the oil seal with SST. SST [09608-30021]

Fig. 10-57

Fig. 10-57

3. Coat the lip with MP grease.

Bushing

Check for wear or damage. If found, replace the case cover.

Fig. 10-59

Fig. 10-59

Input Shaft

Check for wear or damage.

Fig. 10-60

Fig. 10-60

Toyota Landcruiser Restorer

No.1 Counter Shaft & Slotted Spring Pin

Check for wear or damage.

Outer Race & Bushing

Check for wear or damage.

Fig. 10-62

Thrust Bearing & Race

Check for burning, wear or damage

Fig. 10-63

One-way Clutch

Check for wear or damage.

Fig. 10-64

No.1 Counter Gear

Check for wear or damage.

Fig. 10-65

No.2 Counter Gear

1. Check for wear or damage.

2. Check the bushing for wear or damage.

Fig. 10-67

Fig. 10-67

Clutch Outer Disc

Check for burning, wear or damage.

Fig. 10-68

Clutch Inner Disc & Plate

Check for burning, wear or damage.

Fig. 10-69

le as

Winch Drum

Check for damage.

Fig. 10-70

Shift Lever

Check for damage.

Check the bushing for wear or damage.

Fig. 10-71

No.2 Counter Shaft

Check for wear or damage.

Fig. 10-72

Fig. 10-73

Fig. 10-74

No.3 Counter Gear

Check for wear or damage.

No.4 Counter Gear

1. Check for wear or damage.

2. Check the bushing for wear or damage.

Fig. 10-75

Fig. 10-75

Output Gear

Check for wear or damage.

Shift Shaft Retainer, Spring & Ball

Check for wear or damage.

Fig. 10-77

Fig. 10-78

Sleeve Shift Shaft & Pin

Check for wear or damage.

Fig. 10-78

Inner Hub

Check for wear or damage.

Fig. 10-79

Winch Case

1. Check for wear or damage.

Fig. 10-80

Fig. 10-80

Fig. 10-81

Replace The Oil Seal

1. Remove the oil seal.

2. Check the bushing for wear or damage.

3. Check the oil seal for wear or damage.

Replace The Oil Seal

1. Remove the oil seal.

Fig. 10-83

Fig. 10-83

Transmission Gear Thrust Discs

ASSEMBLY

1. Assemble the case cover in the numerical order shown in the figure.

Transmission Gear Thrust Discs

Fig. 10-85

10 Fig. 10-105

1. One-way Clutch

2. Snap Ring

3. Clutch Outer Disc, Inner Disc, Plate & No.2 Counter Gear

4. Clutch Outer Disc, Inner Disc & No.1 Counter Gear

5. Thrust Bearing & Race

6. Clutch Outer Race

7. Clutch

8 No. 1 Counter Shaft

9. Slotted Spring Pin

10. Input Shaft

Fig. 10-86

Transmission Gear Thrust Discs

Fig. 10-86

A Before assembling new inner discs, soak them in automatic transmission fluid, for at least 30 minutes.

Fluid ATF Type F

Fig. 10-87

Fig. 10-87

Fig. 10-88
Fig. 10-89

Coat the outer race bushing with MP grease.

Coat the one-way clutch with MP grease.

Assemble the one-way clutch as shown in the figure

Fig. 10-90

Fig. 10-91

Install the snap ring. - Note -

Confirm that the snap ring is securely installed.

Check the one-way clutch.

Bearing Notch Alignment

Align the notch and tab and assemble the clutch disc to the counter gear.

Fig. 10-95

Hold the clutch disc and plate by hand and assemble the No.1 and No.2 counter gears as shown in the figure.

Fig. 10-95

Fig. 10-96

Coat the thrust bearing and race with MP grease.

Before assembling the outer race, set up the disc flukes.

Turn the No.2 counter gear clockwise and

Fig. 10-98

Fig. 10-99

Fig. 10-100

Confirm that the thrust bearing and race are aligned in the center.

Fig. 10-99

Coat the bearing parts of the case cover with MP grease.

Install a new 0 ring and coat with MP grease.

Fig. 10-100

BHold No.1 counter gear by hand and push in No.1 counter shaft

Fig. 10-102

Fig. 10-102

Fig. 10-103

Fig. 10-104

!\ At this time, align the case cover hole and counter shaft hole.

After assembling No.1 counter shaft if the holes are not aligned, rotate the outer race counterclockwise and align the holes.

Fig. 10-104

Toyota Electric Winch

Tap in the slottled spring pin with a pin punch.

Before assembling the input shaft, wrap the gear with tape.

2. Assemble the winch case in the numerical order shown in the figure.

Fig. 10-106

Winch Gear Landcruiser

1. Winch Case

2. Output Gear

3 Free Spool

4 No.3 & No.4 Counter Gear

5 No.2 Counter Shaft 6. Shift Lever

7 Winch Drum & Spacer

Fig. 10-107

Fig. 10-107

Coat the winch case bushing with MP grease.

Fig. 10-108

Fig. 10-108

Coat the sleeve shift shaft and 0 ring with MP grease.

Fig. 10-109

J

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V,-jf/—

Install the shift shaft retainer and steel ball.

Make sure that the position of the shift shaft retainer is as shown in the figure.

Fig. 10-111

Fig. 10-112

Coat No.2 counter shaft and a new 0 ring with Mp grease.

Tap in No.2 counter shaft.

Fig. 10-113

Fig. 10-113

Tighten the shift lever support.

Fig. 10-114

Coat the spacer with MP grease.

3. Assemble the winch in the numerical order shown in the figure.

Fig. 10-116

Winch Assembling

Fig. 10j 117 10-119

0-120 Fig. 10-121

0-120 Fig. 10-121

Fig. 10j 117 10-119

1. Case Cover

2. Drum Spacer

3. Winch Housing 4 Winch Set Plate

Fig. 10-118

0 First install the bolt in the place shown in the figure.

Fig. 10-119

Tighten each bolt a little at a time, in the !\ sequence shown in the figure.

Fig. 10-119

Tighten the bolts to specified torque.

Tightening torque: 1.5 - 2.2 kg-m (11 — 15 ft-lb)

Tighten the bolts to specified torque.

Tightening torque: 1.5 - 2.2 kg-m (11 — 15 ft-lb)

Coat the drum spacer with MP grease.

Fig. 10-122
Toyota Electric Winch

Fig. 10-123

Tighten the bolts to specified torque.

Tightening torque: 5.0 — 8.0 kg-m (37 - 57 ft-lb)

Fig. 10-123

Check that the drum rotates smoothly.

WINCH MOTOR

MOTOR SYSTEM CIRCUIT

Fig. 10-124

Fusible Link

Magent Switch No.1

Fusible Link

Toyota Hilux Fuse Links Model

Magent Switch No.1

Fig. 10-125

HEATER Fuse

Fusible Link

• Magnet switch

HEATER Fuse

• Magnet switch

Sst 09023 00100
Motor with Magnet switch
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Responses

  • teegan king
    How to remove the fusible link in a toyota hilux 2006?
    7 years ago

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