On another note - does anyone know where some of my missing parts are?

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No, the top plate & the bottom rod plays a very important role in the 2 end housings being held in perfect alignment with each other. If the winch has seen heavy use without the top plate securely in place, this may be your problem now because without it the whole winch assembly can become distorted under load warping this & that out of shape very easily. Anything from the drum shaft being bent to the end housings being warped up or even cracked. The frame rails flex under load as well without the end housings being held in proper alignment. No telling what you may find on a very close inspection. Is the bushing you suspect isn't right pressed all the way in? It should be flush with the outer edge of its bore. Running with the assembly flexing & wobbling may have cracked the bushing causing it to loosen & work out. Running the assembly out of alignment will cause severe oil leakage, even with new seals.N1VSM wrote:After disassembling and reassembling, checking tolerances & such on my LU-4, I'm rather convinced that the bushing on the clutch end of the drum is OUT too far by 1/16". This winch was operated without the top plate in a previous life. My question - is this possible? I've gone through the worm gear housing - checked engagement of the drum drive shaft, and everything else I could think of. Any suggestions? I mean besides pressing the bushing in ...
On another note - does anyone know where some of my missing parts are?