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Discussion Starter #1
After fixing many issues on my winch, the only thing left for it to be good is I need new brushes. I disassembled, sanded, greased the switch and contactor. This seemed to fix the interment issues. When I went to take the winch apart. First the bolt for the yellow cable sheared off. Once I got it open it was obvious the brushes were shot. Not only worn but cracked. The motor and rest of the winch is fine. Clean and grease and I'll have no worries about it. The only problem I have is it seems warn doesn't sell just the brushes. They'll sell the entire motor assembly for $130 but not just the brushes. Has anyone come across this before? I'm sure brushes from a car starter would fit if I can find which one. I just rebuilt the starter on my F150 and the old brushes were close but not the same.
 

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Discussion Starter #2
Since no one replied, I assumed no one knew the answer so I figured I'd share what I did. All the alternator/starter rebuild shops that use to be around are now out of business. I was trying to find brushes from a car since anything atv is always 3x the price. No luck there but then I found a superwinch replacement cap that looked good and I was right. Superwinch 90-10770 BRUSH END CAP × 1 $23.92
Unfortunately you can't just swap caps because the superwinch uses a smaller bearing. The other bad part is the brushes are epoxied in to the cap and you have to destroy it to get it out. Not the greatest but the brushes are an exact match and I am back up and running now
 

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Your thread probably just got missed. This is the first I seen it. Glad it all worked out for you and thanks for coming back with results.

You could of made the other brushes fit as long as they are larger than required. I have done this many times over the years. All you got to do is file down the larger brushes to fit.

Finding brushes today is difficult though, like you found out. The best option I have found is buying brushes for carpenter tools like table saws, mitre saws, etc. Those are still available but still a little hard to find.
 

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Yeah I missed the thread also and I'm surprised you couldn't find some online. Glad you got it fixed a lot cheaper than a new winch.
 
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