[GMFL]

My money is still on the Ratchet gears (#13 and/or 20 on schematic) installed upside down. From what I can tell by looking at the file you posted it is possible. The pawls can only go into the pawl gear one way but the pawl gear assembly will fit into the ratchet gear two different ways. Only one way will work.

You just have to go through and follow that schematic as you reassemble. Test each assembly as you go along. ie. Insert the springs in the pawls, pawls in the gear. Test the spring tension. Push down on the pawl, it should snap right back up. Insert pawl gear assembly into ratchet gear, turn ratchet gear around one way, should go free. Try to turn the other way, should not move. Etc. Carry that through the whole rebuild.

Unless you have parts left over or are missing some, if it worked before, it will work again.

With my winch, even with all the grease on the pawls, and weak springs at least one of the pawls would grab eventually. The winch would not keep slipping backward.

 

[nestorph]

Contrary to the accepted wisdom, you can "fix stupid"--at least in my case. GMFL's comments kept nagging at me so with hope in my heart I went down to the boat yesterday and once again took apart the winch. Sure enough, I had installed one of the gears (#14 in the parts list) upside down. What had fooled me was the indentation routed in the gear that fit the pawl gear about it perfectly. Turns out that the indentation also fits the flanged bush (#13), too and that was its intention! Make the fix and the winch works like a dream. Ten minutes later did the same to the other winch.

One upside: I can strip down and reassemble these babies in no time with my eyes closed.

Thanks to all for your patience and advise! I will now take my tail and drag it off...

 

[hellosailor]

"I had installed one of the gears...upside down"

This is the great thing about DIY. You never have to waste the price of a phone call to bawl out the idiot who made the mistake. (VBG)

 

[nestorph]

Very true. The idiot in my mirror has been bawled out countless times but keeps coming back!