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I've got a working LU-4, but the shift lever doesn't align with the stop holes.
I t's probably either a sprung shift fork or a worn shear pin.

Should I overhaul it, or install it as is and run it till it breaks?
(I think I already know the answer to this, but I need my willpower reinforced)

You know it'll go all fubar when you need it the most... If its an easy fix, and its already off the truck, then just fix it now...

Jim,

I would take the time to fix it now rather than later. You will save yourself time and aggravation in the long run.

Bert

I wish ya'll were wrong - but, I know you're not

Your winch is the sort equipment that lends itself to utility, recovery and the possibility of emergency situations, make it good and make it reliable, no point in "almost" saving property or more importantly life, make it right

MM

I put an LU-4 on my 37 in 1962 back in my search and rescue days. Have never regretted it and only broke it once. Been meaning to put on on the 708 for a looonngg time. I have a talent for procrastination. No point in rushing now.

I vote for a tear down and clean up. Then you know what you have and that it will last for the life of the truck. I bought one from Master Yota (Thanks Ray!) some years ago and after some indecision, disassembled, inspected and did some minor repairs. The shift lever was stuck due to corrosion but cleaned up ok. Although, I don't do a lot of winching, I know it doesn't leak on my shop floor, is up to snuff and will be serviceable when I really need it. There are a couple of very good write-ups around if you don't have one or any experience with these. This is the one I used for guidance:
http://imageevent.com/moosecreekmaple/l ... 421.eagle_
and another ugly one with good pictures... http://www.m715zone.com/vb/showthread.php?t=26151
Jess

I've overhauled them before.
Just lazy.

Fix it right the first time. Which means do it now.

LU-4s aren't cheap, and somewhat scarce anyway, so fix it now instead of inviting trouble (especially with Winter on the way).
Gary

That's true. I paid $150 for this one. The one I got in 1962 was free.

Jess wrote:I vote for a tear down and clean up. Then you know what you have and that it will last for the life of the truck. I bought one from Master Yota (Thanks Ray!) some years ago and after some indecision, disassembled, inspected and did some minor repairs. The shift lever was stuck due to corrosion but cleaned up ok. Although, I don't do a lot of winching, I know it doesn't leak on my shop floor, is up to snuff and will be serviceable when I really need it. There are a couple of very good write-ups around if you don't have one or any experience with these. This is the one I used for guidance:
http://imageevent.com/moosecreekmaple/l ... 421.eagle_
and another ugly one with good pictures... http://www.m715zone.com/vb/showthread.php?t=26151
Jess

I'm glad to hear it worked out for you Jess! I was thinking about it the other day, and wondering if you'd managed to get it cleaned up and installed...

One of the stud holes for the 1/2-13 x 1/2-20 double ended studs that mount the side brackets on my LU-4 is wallowed out.
As I see it, I have two feasible options
1) Overbore and helicoil back to 1/2-13
2) tap case for oversize double-ended stud 17/32-13 x 1/2-20 (stud might be hard to find)

Any thoughts?

Depending how enlarged the threaded hole is I would do the Helicoil option first. If it's too enlarged for the Helicoil, I would go with a EZ Lock threaded insert.

Bert

Presently, hole size is such that a 1/2-13 will 'hold' or 'take', but wobbles. Not very strong and could easily strip.