Warn winch Problems

[bensdive]

My warn winch won't Put the cable back it starts but its like it loosing power the you try again and it will for a small time then stop Forany help or advice
thanks The land rover gods seem to be smiling on me the coolent leak has stop and we had a great trip to Ngarkat The old disco handle all well.
All the best
Ben

[George130]

Glad you had a good trip. Don't know on the winch. I only have hassles with mine when it winds all the rope in on the one side and it gets to full. All I do then is wind it out and wind it back with a little more care.

[DEFENDERZOOK]

are the main power cables nice and tight.....?

are the brushes in the motor ok.....?

has the gearbox ever been serviced on the winch.....may need a good clean and grease.....

[bensdive]

The first time I had to use it . it was on the car when I bought it.
Ben

[DEFENDERZOOK]

it will just be full of rust and crud......

it will need to be pulled appart and cleaned then greased and re assembled....
which should then work like new.....apparently this needs to be done once or twice a year.....
but i dont think it ever happens until the winch stops working.....
its not a hard job.....but it will take a while to do...and make sure to disconnect from the battery before you start.....


what it is is....all the dust from dirt roads....river crossings.....rain....sun....
it just gums up all the workings in the motor and gearbox of the winch.....


if you are thinking of replacing the winch......i will gladly take the old one off your hands.....:D

[DaveS3]

Easiest thing to check is the solenoids. Clean them real well, then use an electrical contact spray. You will have to unwire ect - very easy. Check the cables.

If its not the solenoids check the motor. It is worth servicing anyway if you dont know the history, not an item you want to let you down when you need it most.

Dave.

[Martin]

I recently had a similar issue with my XD9000. I took it apart, and all the brushes were black, and the whole thing was full of crud and sand and grit. I cleaned it all up, put it back, and now it's better than new.

When you have taken the winch off, mark with a permanent marker a small dot or mark on the motor case, and the main body, as there are several positions you can put it back together. If you get it wrong, you will find that your wires may not reach, and you will have to take the winch back off, take it to bits again, refit the motor cover in the correct position, and try again. I learned the hard way...

I found it easier to remove the winch cable first, to make the winch lighter, as without practice, it is tricky to get on and off the car.

Good luck
martin

[discoute]

What model is your winch?

If the motor runs you can forget about the soloniods, they either work or don;t. If The winch has an unknow history, clean and service is a good start.

If your winch is an old low mount warn you must not remove the brake assembly from the drum. They are loaded withinn the housing.

Can be the motor or fautly/worn brake assembly. Inspect and clean the motor first. Brushes and parts can be ordered from ATECO in sydney they carry a large stock of warn parts. A truck electrition will be able to sevice the motor if you don't want to touch it. General auto elec should also be able to help. If you do the motor be sure to place the drain to the bottom as you place it back on. the drain will be found at the engine place end of the motor. only small.

And yes the winch should be serviced about every 12 months. How do I know this. I am the Tmax Warranty Repair agent. And I service warn as well.

If you sevice the gearbox degrease all parts and regrease with a quality grease, It helps to place an oil treatment in the box, couple of table spoons will do, Some thing like Morreys or auotmotive gearbox additive. This will help keep rust from the gears should the winch get water in it. Dont over grease the gears, the winch will be hard to free spool with to heavy or to much grease. Use an extreme pressure grease.

hope this helps.

glen

[p38arover]

Here are the diagrams for the winch wiring. These are copyright by me and another bloke so they are not for commercial use (he did one drawing, I did the other) - I'm sick of people using my photos and articles commercially without asking.

http://www.members.optusnet.com.au/thebecketts/rover/pix/warn-sol1.pdf

http://www.members.optusnet.com.au/thebecketts/rover/pix/warn-sol2.pdf


Oh, by commercial use I mean giving it away and pretending it is yours. I don't mind if you use it in your workshop.

Ron

[crump]

What model is your winch?

If the motor runs you can forget about the soloniods, they either work or don;t. If The winch has an unknow history, clean and service is a good start.

If your winch is an old low mount warn you must not remove the brake assembly from the drum. They are loaded withinn the housing.

Can be the motor or fautly/worn brake assembly. Inspect and clean the motor first. Brushes and parts can be ordered from ATECO in sydney they carry a large stock of warn parts. A truck electrition will be able to sevice the motor if you don't want to touch it. General auto elec should also be able to help. If you do the motor be sure to place the drain to the bottom as you place it back on. the drain will be found at the engine place end of the motor. only small.

And yes the winch should be serviced about every 12 months. How do I know this. I am the Tmax Warranty Repair agent. And I service warn as well.

If you sevice the gearbox degrease all parts and regrease with a quality grease, It helps to place an oil treatment in the box, couple of table spoons will do, Some thing like Morreys or auotmotive gearbox additive. This will help keep rust from the gears should the winch get water in it. Dont over grease the gears, the winch will be hard to free spool with to heavy or to much grease. Use an extreme pressure grease.

hope this helps.

glen

So, if I'm after a new Tmax winch, I should contact you for a great deal???:D :D

[mr_sav]

What model is your winch?

If the motor runs you can forget about the soloniods, they either work or don;t. If The winch has an unknow history, clean and service is a good start.

If your winch is an old low mount warn you must not remove the brake assembly from the drum. They are loaded withinn the housing.

Can be the motor or fautly/worn brake assembly. Inspect and clean the motor first. Brushes and parts can be ordered from ATECO in sydney they carry a large stock of warn parts. A truck electrition will be able to sevice the motor if you don't want to touch it. General auto elec should also be able to help. If you do the motor be sure to place the drain to the bottom as you place it back on. the drain will be found at the engine place end of the motor. only small.

And yes the winch should be serviced about every 12 months. How do I know this. I am the Tmax Warranty Repair agent. And I service warn as well.

If you sevice the gearbox degrease all parts and regrease with a quality grease, It helps to place an oil treatment in the box, couple of table spoons will do, Some thing like Morreys or auotmotive gearbox additive. This will help keep rust from the gears should the winch get water in it. Dont over grease the gears, the winch will be hard to free spool with to heavy or to much grease. Use an extreme pressure grease.

hope this helps.

glen

Discoute,

Does this apply for the 9000 Magnum Winch as well? Badged by WARN.

I recently bought one, now on my ol' girl (Landy).

[WOLLAPIT85]

Quote:
Originally Posted by p38arover
Here are the diagrams for the winch wiring. These are copyright by me and another bloke so they are not for commercial use (he did one drawing, I did the other) - I'm sick of people using my photos and articles commercially without asking.

http://www.members.optusnet.com.au/t.../warn-sol1.pdf (http://www.members.optusnet.com.au/thebecketts/rover/pix/warn-sol1.pdf)

http://www.members.optusnet.com.au/t.../warn-sol2.pdf (http://www.members.optusnet.com.au/thebecketts/rover/pix/warn-sol2.pdf)


Oh, by commercial use I mean giving it away and pretending it is yours. I don't mind if you use it in your workshop.

Ron


Did you get permission from Warn to use their logo on your drawings..:lol: :lol: :lol: :lol:

[Maggot4x4]

Do a load test on the battery, it could be that and not the wich at all.

[p38arover]

Quote:
Did you get permission from Warn to use their logo on your drawings..:lol: :lol: :lol: :lol:

Oops!

The difference is that I'm not doing anything commercially with the diagrams.

Ron

[discoute]

Discoute,

Does this apply for the 9000 Magnum Winch as well? Badged by WARN.

I recently bought one, now on my ol' girl (Landy).

The magmum winch is a later model winch and is 1 off the best on the market. Thing with warn is they are well made with hardened gears. Like the TMAX winch in 9500 and 11000 pnd jobs. the 6500 and 8500 has sintered gears not nearly as strong as Warn or The larger Tmax. The later model Warn And Tmax Have removable Brake assembly and can be removed from the drum for service and replaced in the same manner. The Tabor winch from warn is also proving to be a good buy, however I am not sure about gear strenght.

Repco winch and other cheapies are of sintered gears and are generaly poor in build. they are ok for occational use but for serious offroad and trips to desert or into remote area use only good quality winchs. There are many claims that some of the cheap winchs come from the Tmax factory this is just BS, Tmax have been making industrial Winchs for over 60 years and sell only Tmax badged winchs. The cheapies are just that and from another chinese Winch factory. I have have several of these winchs supplied to me for testing in the field over the last couple of years. Instructions work the winch and destroy it, see how strong they are. On one occation the winch lasted only 24 mtr pull and destroyed the gear box. All Cheapies I have tested are just that cheapies, You get what you pay for.

And yes I can offer Tmax and Warn winch to forum members so long as I don;t offend any members in the same business.

If you wind all of the cable to the one side of the drum you risk breaking the motor plate or the gearbox plate. I repair more of these than any other winch breakages.

glen

[discoute]

Have just confirned with Warn the gears in the new TABOR winch case hardened, so will be stong like all other warn product.

glen

[George130]

OK. How do you confirm which winch you have. I know mine is a warn but havn't confirmed it is the 12,000lb.

[discoute]

OK. How do you confirm which winch you have. I know mine is a warn but havn't confirmed it is the 12,000lb.

Serial no. will help I have a list of these and can identify it for you. If go on serial no when ordering parts you can' t go wrong. the no.s are generally on the gear box housing.

glen

[mr_sav]

Discroute.

Cheers for your input. I had taken advise of a few sales people across different stores. I was originally concerned that the Magnum may have been a Warn Badged unit of the cheaper chinese variety.

You have aleviated my concerns.

Regards,

mr_sav.

[discoute]

Discroute.

Cheers for your input. I had taken advise of a few sales people across different stores. I was originally concerned that the Magnum may have been a Warn Badged unit of the cheaper chinese variety.

You have aleviated my concerns.

Regards,

mr_sav.

I am here to please, so my wife keeps telling me.:) :) :)

glen

[bensdive]

Thanks for the help It turned out to be the battrey .I replace it and the winch is working fine Even if my pocket is a lot lighter being an Odyssey Battrey is the only one that will fit in the space.
Thank all All the best
Ben

[discoute]

Thanks for the help It turned out to be the battrey .I replace it and the winch is working fine Even if my pocket is a lot lighter being an Odyssey Battrey is the only one that will fit in the space.
Thank all All the best
Ben


Mate sounds like it may have been cheaper to rebuild the winch.Glad to see you found the problem.

glen