Winch motor broke... and manual operation

[Project13thirty1]

First trip planed for Friday in our New to us hw27ks... opened it up to pack today and make some repairs... boom wench drive gear snapped off. Noone within reason has a replacement for me to go get quick. Had to order one straight from the mfg. Does anyone know if they changed the shaft design on these motors? It's a 3/16 shaft between the motor and the gear, no wonder alot of people have them snap off. I've got a friend that's a machinist so I'm gonna see if we can make some "improvements" to the design. If it works out I'll keep the new one as a spare or sell it if we can make the old one work better.

I did figure out a way to work these things manually. If you tighten the inner nut on the clutch adjuster and lock the outer nut aginst it, you can put a rachet or a wrench on it and still be able to open the camper. Turn it left to go up but make sure you are grabbing the inner nut or both at the same time or the outer nut will just loosen up. Going down I'll have to but I believe you should be able to put your wrench or rachet on it and open the pawl on the clutch and let it down slow. Might have to let the pawl lock back in each turn.
If that dosent work I'll try to figure something else out. Will update if it works.

[Project13thirty1]

well i got the new motor in from powerwinch before i had to lower the roof on the camper so i didnt test taking it down manually. i also realized that the normal manual operation of the winch is putting the stabilizer jack wrench on the wench drive gear... that will not work if the gear breaks off. also it seems the design of the motors has not changed for the p92001 winch. i was able to get my machinist friend to pin and weld the gear back on the old motor so it should be much stronger. im going to keep it in the camper as a spare.