for Many of Our L.I. Sound
Offerings—
Servicing a Winch—
Step-by-Step Instructions
Below is a photo sequence of a mid-80s
model, Lewmar 40 self-tailing winch being taken apart and
serviced. Though you may not have Lewmar winches, the overall
process is similar for most winches. The parts in yours
may look a bit different, and there may be a few things
specific to each winch, whether another brand or another sized
Lewmar, the pictures below can help you understand the
involvement required to properly service a winch.
Most times this service is done right on
board, since removal of the winch is more often than not,
impractical. But, frankly, a winch that can be serviced off the
boat, on a bench, allows for much more thorough cleaning. If
yours can easily be removed, take them home over the winter for
better access (and no concerns about losing pieces overboard).
Or, if this process looks like too much for you, send them to
us. This is what we’ll be doing to them:
Unscrew the four top cap machine screws.
This step can be quite different for other Lewmar series/models
winches and other brands.
Lift off the top cap. Underneath the top
cap you’ll find a 2-piece collet.
Separate the two halves of the collet from
the main spindle (that is resting on it) using a screwdriver
blade and remove each half
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The stripper arm is now just resting in
position. Lift it off the main spindle to remove it.
The winch drum should now just lift off
exposing the guts of the winch.
Depending on how long it’s been since
the previous service, or how much lubricant was used, you
should find everything in fairly acceptable condition as we
found with this winch..
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The bearing set can now be removed.
Sometimes it’s three bearings, sometimes only two. In
this case, there are two bearings and a spacer between them.
They will all lift off together when lifted up from the bottom
bearing. These two bearings are interchangeable. Do not worry
which went on top and which on bottom.
Underneath the bearing set is a flat
bushing. It may not be obvious due to grease build up. Remove
this by lightly lifting the edge with a screwdriver or knife
blade to break any seal (from lubricant). It will easily slide
up and off the spindle.
Once the bushing is removed, the tops of
two gear spindles are exposed. (Smaller winches will only have
one.) Work a screwdriver blade in under the lip of either of
the spindles and gently pry it up.
Pull it all the way out. Once removed, the
gear set that rides on it will be free.Be careful the gears
don’t fall out.
Reach in and grab the large gear and pull
it out of its seat. The whole gear set will come out with it.
Now repeat the process by removing the 2nd
gear spindle. Lift under lip with screwdriver again to pry up
and out.
Remove 2nd gear set. They, too, will come
out as one unit, but again, be careful. The bottom gear can
easily separate, with pawls and springs flying every which way.
Hold both gears together as they are removed.
The main spindle should now be free to pull
out from the bottom or the top (depending on winch type).
Slide the bushings off the spindle and
inspect for cracks. Note location of bushings before sliding
off to be sure they are put back in the same area along the
shaft upon reassembly.
Separate the 1st gear set. Slight spring
tension holds the smaller pawl gear into the larger gear. As
you pull up on the smaller gear, the spring-tensioned pawls
that are seated within that gear will spring out as they clear
the edge of the lower gear. Be careful they don’t fall
out of their seat yet. Sometimes, if there is a broken pawl
spring, the pawls can fall out when pulled up. So if working
around the water, make sure you have the area contained.
Here, we see the pawls sticking out.
Difficult to see are the pawl springs which are holding the
pawl in that position. To remove the pawls, you must compress
the springs and slide the pawls and springs out as one piece.
We’ll get to that in a minute. First we’ll separate
the other gear set.
To separate the 2nd gear set, just pull the
two gears apart. However, before separating, it is safer to
flip over the gear set so the gear that was on top is now on
the bottom. This way, when the two are pulled apart, the gear
holding the pawls is easily visible, allowing you to keep an
eye on any parts that look like they are about to fly.
To remove each pawl, reach in with a scribe
or small screwdriver to compress one side of the pawl spring
arm against the pawl as shown here, then lift out the pawl and
spring together while squeezing. This is normally where you
will lose a spring, so cup your other hand over the whole
process to catch the spring if it tries to take off. Remove all
pawls in the same manner. See the next photo for a better view
of the spring. Click here.
