Did a lot of work on the winch today. I'm waiting on a response from Warn. My serial number is lower than the ones they list on their website. Not sure what that means, but hopefully they email me back next week.So here's what I started with.Warn XD9000i, Serial #359923. This thing has seen some better days. There is a lot of chipped paint on it. If you look on the left side of the picture, you'll see that at some point, the wire ripped through the body and cut a chunk off. I also noticed that one of the screw holes in the gear housing is cracked. Overall, it was in pretty crappy condition. Let's take it apart and see what we find.First, we'll take the gears out.Ok, not the worst. The teeth are in good shape. Not too much rust here (note that this was after I wiped it down a little bit). Let's look at the gears themselves.Yup. This should be interesting. Let's remove the outer gear.Mother of god. Let's take more apart.So the good news is that all the teeth seem to be in good shape. At some point, some water must've sat in here and the PO probably didn't bother to get it out. I dont think this winch has ever been opened really.So I spent several hours cleaning this gearbox. Here are the results:Much better. I won't be turning this guy on for a while, so I didn't grease it up yet. There's a special kind that Warn recommends that I will order next week. So now that the gears are done, let's look at the motor on the other side.I'll be honest here and say that I'm not sure if it's good or bad. It looks like the inside of a motor. Nothing looks burned I guess. I will say that I'm pretty sure the PO wasn't entirely honest with me. He told me that this thing ran fine, but the wires that connected it were torn in half and connected with painters tape.There's no way this thing has ran lately. So let's open up the solenoids and look at them.I immediately regret this decision. At this point, I decide that there's no way in hell I trust any of this wiring. Most everything was extremely corroded and there were wires just hanging there not connected to anything. I mapped out all the connections for reference and pulled all the wires out. I also decided to take the entire body apart to inspect it.The roller wasn't really bad at all. Some grime and lots of dirt, but no issues that I could see. The 2 edge pieces were totally fine. Same dirt as everything else.After I got them cleaned up, I started to put it all back together... and here is how she sits now:Can't really tell anything different on the outside, but the inside is a hell of a lot cleaner.So really to rebuild, here's what I'm pretty sure I have to order:- all new wiring.- remote.- new motor.- clutch lever.- bolts for the gear box. It only has 3 bolts when there should be 12 or so.- long bolts to keep the top cover attached. I have none when there should be 2.- 2 bolts to attach the center solenoid holder to the body. There should be 4 but I have 2.- center hex rod.- 2 nuts for the bottom legs to attach them to the winch mount. There should be 4 but I have 2.- all new gaskets.- winch mount.- cable.- fairlead.It looks like a lot, but I'm pretty sure most of it is going to be cheap (with the exception of the mount, fairlead and cable). I also think that I'm going to end up repainting this thing. The paint is chipped in a lot of spots and I don't want it rusting. I'm really, really, really happy with how the gears look. I didn't notice a single chipped tooth. The center rod seemed to be worn a little bit, so I'm considering replacing that. I'm still not sure if the motor even works, but we'll find out when I get it hooked up.So that was my evening project. I used a lot of Simple Green and an entire pack of microfiber towels. Well worth it though. I really like how these things are built. They seem extremely solid and I can definitely see why they last a long time. I'm also researching what type of cable I want. I really like the synthetic rope option, but that is a hell of a lot more expensive than the normal steel line. I'm hoping I can get this all together and on the jeeper before I drive it up to Pennsylvania at the end of December. Fortunately I got a little award at work that came with some money, so I can have a little extra fun with the jeep than I had initially planned.