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  #1  
Old 02-06-2017
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JeepUniq JeepUniq is offline
(Dan) (KJ7DAN)
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Default Warn Powerplant Woes
As some might know, my pride and joy Warn Powerplant winch and compressor combo decided to transform itself into a coffee grinder. Not that was any good at it, but the noise it was making was very convincing.

I delayed and delayed pulling it off the bumper, but over the weekend I finally did. A few months back I searched Warn's website and found that it had a service center in Phoenix, so I loaded the damn pig in the Jeep and searched again to get the address but found that that center wasn't listed as a factory service center anymore. The closest one is in California (you know our westerly Peoples Republic neighbor) and shipping a >100 lbs is almost cost prohibitive. So I took matters into my own hands and took the damn thing apart.

BTW, I typically "buy American" to (a) support domestic businesses, and (b) because I found that Chinese crap is usually just that, compared to Made in USA. Well, Warn is Made in USA, a legend in the offloading community, so it must be top notch quality, right?

Well, upon disabling it, I can attest that the engineering and build itself is really solid, no plastic parts, nice fits, etc. However the assembly seems to have been done by a monkey: most screws were loose. Even more, none of them had even a trace a Loctite. Not blue, not red, nothing! It's like the Warn factory ran out of Loctite when assembling my unit. No nylocs, no split washers either. I mean this is an offroad winch?!? BTW, no real seals either, but surprisingly the grease was very clean despite this.

"Dan, enough with your didactic rant! What the hell was making the grinding noise?"

Well, the compressor has (had) an aluminum gasket attached to the top of the piston. Via a bolt. No loctite. No split washer. Lots of vibration. Yep, the damn screw came out and trashed the piston along it the valve (which it was trying to grind perfect for an espresso). This semi-seized the piston.

I'm not done yet with the full disassembly, so the carnage might've affected the belt that engages the compressor as well.

More to come.
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  #2  
Old 02-06-2017
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JeepUniq JeepUniq is offline
(Dan) (KJ7DAN)
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Default Re: Warn Powerplant Woes
Surprisingly, the belt is in perfect shape, so I only need to replace the piston and the piston head and valve. Should receive the parts this week.

Another observation: even tough I'm critical about the way the unit was carelessly assembled, I have to say that I really, really missed the compressor. Since the Warn was out of commission I've played to several other compressors: Puma PD1006, Superflow MV-90 (similar with the Smittybilt 2781) and found that none match the PowerPlant in speed and convenience.
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  #3  
Old 02-06-2017
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theksmith theksmith is online now
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Default Re: Warn Powerplant Woes
did Warn send you the parts for free?
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Old 02-06-2017
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Default Re: Warn Powerplant Woes
Not exactly. I didn't bother to call them, but I will get them from Warn free via another source.
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Old 02-06-2017
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Default Re: Warn Powerplant Woes
Dan, take some pics inquiring minds want to see. Your work on this rebuild will be much better then some one else's work.

G
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  #6  
Old 02-06-2017
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Default Re: Warn Powerplant Woes
Sure G. The main diagram from Warn's website is:

Screen Shot 2017-02-06 at 8.26.53 PM.jpg

The piston is #38.

Here're some pics of the piston, the top of piston head, the top of the compression chamber, the compression sleeve, and lastly what's left of the valve:

p head.JPG

c chamber head.JPG

cyclinder 2.JPG

p head bolt damage.JPG

p head bolt strip.JPG

p head gasket.JPG

valve.JPG

Note how the bolt hole got destroyed on the piston.

Some pictures of the rest of the bolts, nice and clean w/ no trace of loctite.

bolts 1 - Feb 6, 2017, 8-51-04 PM.JPG
bolts 2 - Feb 6, 2017, 8-51-04 PM.JPG
bolts 3 - Feb 6, 2017, 8-51-03 PM.JPG
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  #7  
Old 02-07-2017
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Default Re: Warn Powerplant Woes
Dan,
Thanks for posting this up. I am following closely due to having this Warn also.
Roy
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Old 02-07-2017
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Default Re: Warn Powerplant Woes
Dan, thanks for posting this info and the photos.

I hope you email or talk to Warn through your sources and find out if it's expected for nothing to have threadlocker, nylocks or lock-washers... I'm hoping yours represents a fluke or a bad batch. Otherwise it would certainly seem like a very poor design decision considering the vibrations a compressor must endure.
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Old 02-07-2017
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Default Re: Warn Powerplant Woes
That's some heavy scoring right there
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Old 02-07-2017
johnpa johnpa is online now
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Default Re: Warn Powerplant Woes
can you hone the cylinder?
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