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View Full Version : 12v Electric Recovery Winch - replacing broken terminal stud and reconnecting interna


twr7cx
20th March 2018, 09:29 AM
Many many many years ago I managed to snap one of the electrical terminal studs (brass?) on my Ironman 9,500lb winch. Wasn't too much of an issue at the time as I just took the second nut off (that locks the stud to the body barrel), put the cable terminal straight on and did it up. That's held up and worked for six plus years now until this weekend when I needed to remove the winch. The nut had rusted to the stud so when I tried to undo the nut it instead spun the entire stud (as it didn't have a lock nut on it to assist in keeping it in place due to being removed years ago) and internally broke off the electrical connection to the studs head:

https://www.aulro.com/afvb/images/imported/2018/03/333.jpg
https://www.aulro.com/afvb/images/imported/2018/03/334.jpg
https://www.aulro.com/afvb/images/imported/2018/03/335.jpg
https://www.aulro.com/afvb/images/imported/2018/03/336.jpg
https://www.aulro.com/afvb/images/imported/2018/03/337.jpg
https://www.aulro.com/afvb/images/imported/2018/03/338.jpg

Thankfully it all disassembled relatively easily and neatly. I'm not sure where I would source a replacement brass stud - it needs to be about 10mm or so longer than what can be seen in the pictures in order to fit the locking nut back (otherwise I might just end up repeating this issue again in the future), has a hex and square shank on it (the insulation bushing in the winches body barrel is suitably square).

Then I believe that I need a 'stud welder' to reconnect the electrical wiring to it's head as apparently solder doesn't hold up in the heat when the winch is running in full load.

Anyone done such a repair before and able to advise on any parts?

The alternative is an entire replacement motor (e.g. 12V 6.0hp Winch Motor with Motor Base for Winch 4WD [12MB] - $175.00 : 4x4Point, Australian Online-Shop for Jeep Parts and Accessories (http://4x4point.com.au/cart/index.php'main_page=product_info&cPath=20&products_id=39&zenid=htjjhctuuou2orq1ionupg47l5) ) while they're sold out, but if that price of $175.00 is an indicator I'd probably then be worth getting an entire new winch from 4WDSupaCentre at $300.00ish rather... I would be suprised if the Ironman winch isn't just a rebadged mass made model so might get lucky finding a replacement motor to suit if I keep looking.
Dorian
20th March 2018, 10:11 AM
Your on the money with the not soldering.
I'd try to find an auto electrician who will rewind starters. They will probably have the replacement stud and can do the spot welding.
Any general motor re-winder might have the part if your lucky. Look under Electric Motor and Generator repairs.
If you can get the stud but not the spot welder, you can TIG it on, if you can find someone with a TIG.

Cheers glen
twr7cx
20th March 2018, 10:21 AM
Thanks Glen. I'm planning to head out to Star Electrics which are a motor rewinder out in the industrial area this afternoon. See how I go.
Tombie
20th March 2018, 10:38 AM
I have a suspicion that it will be cheaper to purchase a new motor..

Please let us know.
twr7cx
20th March 2018, 11:55 AM
I have a suspicion that it will be cheaper to purchase a new motor..

Likewise, but so far I haven't managed to find anyone with a suitable replacement motor in stock. Has highlighted to me how serviceable Warn winches are as every component for them seems to be readily available.

Worth a shot seeing about having it repaired first though...
Tombie
20th March 2018, 12:12 PM
Have a look at Bowmotors. Bloody good kit.
Ancient Mariner
20th March 2018, 04:01 PM
Get a sleeve nut silver solder the connection back on.Put it back together with anti seize and use a short bolt to connect the cable to the sleeve nut



AM
twr7cx
21st March 2018, 10:30 AM
Called into Star Electric yesterday. The guy there tells me that they don't do small automotive stuff normally, but he has a contract that should be able to make up a replacement stud (as the current one has about 12mm that snapped off it) and then they will be able to reattached it without an issue. I enquired if the price would be scary and he says not. Might of gotten lucky. Will hear back in a few days.
twr7cx
28th March 2018, 10:21 AM
Received the motor back from the shop yesterday. $27.50 in labour from them for the job but $88.00 charged but their supplier to have the new stud machined up. Overall, not too bad. Has repaired both a snapped stud and broken electrical connection on the winch for me.

Although with the new winches being so cheap these days it is difficult to justify the expenses of repairing old one when new ones include the new rope and warranty etc.
Sideroad
4th April 2018, 06:32 AM
Received the motor back from the shop yesterday. $27.50 in labour from them for the job but $88.00 charged but their supplier to have the new stud machined up. Overall, not too bad. Has repaired both a snapped stud and broken electrical connection on the winch for me.

Although with the new winches being so cheap these days it is difficult to justify the expenses of repairing old one when new ones include the new rope and warranty etc.Over all that worked out great.
The machining price is very reasonable considering most shops charge more than that just for setup of material in the lathe.
I can see the long term value of winches that have quality spare parts support.
I'm going to be running an old Thomas electric in the front and generic cheap winch on the rear.
At least I can still get parts for the Thomas.