Lug-All U-Frame Pawl Replacement

Like many of the components on a Lug-All come along ratchet winch hoist, the U-frame pawl can be replaced if it becomes worn out or damaged. The U-frame pawl is responsible for turning the drum by engaging with the teeth as the handle travels its arch. It is a crucial component for the winch hoist to operate properly, and it undergoes frequent wear and impact during operation. It is important to maintain the U-frame pawl and replace it if necessary to keep a Lug-All winch hoist working smoothly and safely.

To replace the U-frame pawl, you need needle-nose pliers, a 1/8-inch punch, and a hammer. The first step is to remove the hoist handle. With the handle removed, the next step is to remove the U-frame pawl shaft. For a Lug-All winch hoist with an internal reversing lever, the U-frame pawl shaft is secured with a c-clip. For a Lug-All winch hoist with an external reversing lever, the U-frame pawl shaft is secured with a c-clip and two roll pins. Follow the steps below for whichever style of hoist you have.

Internal Reversing Lever

Step 1:

Use the needle-nose pliers to remove the c-clip from the U-frame pawl shaft. Slide the shaft out of the U-frame and remove the components. Discard the c-clip, U-frame pawl, reversing lever, flat washer, and U-frame pawl shaft. Save the U-frame spring and spring support roll.

Step 2:

Remove the new hardware from the U-frame pawl replacement kit. The kit includes a new U-frame pawl, U-frame pawl shaft, reversing lever, and roll pin. The new pawl shaft will have a through hole for the roll pin.

Step 3:

Partially insert the new U-frame pawl shaft into the U-frame.

Step 4:

Slide the spring support roll that was removed in Step 1 (tapered end first), the new U-frame pawl, and the new reversing lever onto the shaft. For easier assembly, install the reversing lever with the 1/8-inch through-hole facing upward. Slide the U-frame pawl shaft completely into the U-frame.

Step 5:

Hold the new components to the right with the U-frame pawl tip and reversing lever facing down and insert the U-frame spring into the U-frame.

Step 6:

Slide the spring into the slot on the reversing lever and the legs of the U-frame pawl, using the punch as an aid.

Step 7:

Align the through-hole in the reversing lever with the through-hole in the new U-frame pawl shaft and insert a new roll pin. Hammer the roll pin into the reversing lever and U-frame pawl shaft. The roll pin should be flush with the surface of the reversing lever.

External Reversing Lever

Step 1:

Use the 1/8-inch punch and hammer to remove the roll pin from the external lever and remove the lever from the U-frame pawl shaft. Use the 1/8-inch punch and hammer again to remove the roll pin from the spring support roll.

Step 2:

Use the needle-nose pliers to remove the C-clip from the U-frame pawl shaft. Remove the U-frame pawl shaft and the other components from the U-frame. Discard the used C-clip, roll pins, U-frame pawl, spring support roll, flat washer, and U-frame pawl shaft. Save the U-frame spring and external reverse lever.

Step 3:

Remove the new hardware from the U-frame pawl kit. The kit includes a new U-frame pawl shaft, U-frame pawl, spring actuator, spring support roll, and roll pins.

Step 4:

Partially insert the new U-frame pawl shaft into the U-frame.

Step 5:

Slide the new spring roll (tapered end first) onto the shaft, followed by the new U-frame pawl and the new spring actuator. Slide the U-frame pawl shaft completely into the U-frame.

Step 6:

Hold the new spring roll and U-frame pawl to the right and rotate the U-frame up. Insert the U-frame spring into the U-frame and slide it into the legs on the U-frame pawl, using the punch as an aid. Rotate the U-frame back.

Step 7:

With the U-frame spring in place, the spring actuator slot can slide onto the U-frame spring. Align the 1/8-inch through-hole in the spring actuator with the 1/8-inch through-hole in the U-frame pawl shaft and insert a new roll pin. Using the hammer and 1/8-inch punch, hammer the roll pin into the spring actuator and U-frame pawl shaft. The roll pin should be flush with the surface of the spring actuator.

Step 8:

Slide the reversing lever onto the U-frame pawl. If the external reversing lever is a 587 hot stick lever, the “W587” must be facing outward when installed. Align the 1/8-inch through-hole in the external reversing lever with the 1/8-inch through-hole in the U-frame pawl shaft and insert a new roll pin. Hammer the roll pin into the external reversing lever and U-frame pawl shaft. The roll pin should be flush with the surface of the reversing lever.

Reinstall the handle, and your Lug-All winch hoist ready to use.