gears are stripped, they can be replaced
Warn has plastic gears/dogs.......you probably have the leading edge of the teeth worn or broken off but the rest of the gear is in tact.... it will work fine untill there is load applied then the teeth will slip against each other....... Pull it apart and replace the worn gear....... should be able to order a kit from warn for your winch....sometimes the kit is as much as a new winch....and sometimes the OEM parts (gears) are a little different so as the only option is to replace them in complete sets..... even if one gear looks fine you must replace both...... but keep the spares just in case...... hope this helps ya out.
. The end cap will run you about $43 on average and you might as well change the drum bushings for $5 (p#9)while your at it. Clean everything up very well before putting it back together. I use a heavy wheel grease to pack the gears with when I do it. I give this project rebuild a time frame of two beers (45 min.) Good Luck and here's a parts list for ya .
Money baggs!!
