Thread: Warn winch Problems

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.

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.....

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

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.....

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.

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

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

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/t.../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