Hello again and with thanks to Old Magnet, the winch plug should be delivered tomorrow. Eddie B, you have me on the right road. In order to replace that plug, it seems frozen in place, can i drill and tap it to remove it? Or do I get to pull the side plate? if I do that, do I need to support the drum?
I am currently playing with trying to remove the winch cable from the drum and it is a PITA.
I have drilled and tapped it for a slide hammer and no such luck coming out.
It's stuck real good. It wobbles at either end and even slides back and forth but will not pivot out.
Trying to upload a photo is not working right now.
Any suggestions?
Hot wrench?
If I hot wrench it, any seals that may be damaged?

Drum shaft is still supported by internal bearing and cage if you pull the cover.

Maybe a pic?
So I have butchered it thus far and still stuck.
Before I go nuts with the hot wrench and burn out the internal wires to collapse the ferrule...
Yeah. The thought of molten metal falling into a winch drum is really not my idea of a future good time.
Any suggestions?

Let's try this again. . . .

Thank you for the response Old Magnet. I was hoping you would say that I could safely pull the side cover.
I suppose once I get the old winch cable ferule out, I will get the plug tomorrow and pull the side cover to install that.
Hopefully I can get this cable off today and get the new winch cable also tomorrow.

molten metal shouldn't fall into the drum. why dont you just widen that gap and then heat the ferrule until glowing and use a big punch or chisel to collapse it just a little and pry it out?

The drum sounds hollow behind it.
I am tempted to torch off a section of the ferule on the front, then see if i can then remove the wires followed by collapsing the ferule for removal.
Not pretty and really hesitant to foul things up adding to the repairs.

your not going to hurt anything. cut a slot in that Ferrel and while it is cherry red beat it down with a big hammer and heavy punch. then pull it out. no need to melt out the cable.

The lock bolt needs to come out to release the lock and then the ferrule.
I see threads, is that where to lock bolt was or have you drilled and tapped?
I don't see any reason why you can't torch the ferrule. It sits is a blind pocket.
Try not to damage the lock as it might be hard to replace.

You will need a seal #5F3106 for the small cover and a 2J0157 seal for the oil passage in the large cover. I don't see a gasket call out for the large cover.

Hi Team,
winches came to me for repair/upgrade with cables removed so I have no experience of the clamping arrangement.
I do have a 57 winch Parts Book and that shows a bolt and clamp arrangement that I seem to recall.
I also have a Service Manual that suits the following winches :- 55-6-7-8 and 9 winches and that does not show a view of the cable clamp area either.

Definitely a 54 Winch Operators Instruction Book would show how to clamp the cable. Can the Dealer Parts Dept.. or Used Equipment Dept. get you a photocopy, or let you view on micro film of the winch OMI?
If what you show is a tapered head bolt then one would reasonably assume that the nut or what ever on the other side of the drum wall would be accessible from the other side but I am fairly sure there is no where to access that style of device.
I guess you have tried to turn the rope ferrule to roll it out from under the locking device.
One would reasonably assume that it is a simple device and so would be easy to use.

Sorry, this is all I have to offer at this time.


Regards,
Eddie B.