Winch Repair?

[sn4cktime]

So here's the situation.  Winch power spools out, won't power spool in, and won't switch to free spool.  The solenoid clicks for both directions when using the remote so hopefully that rules out electrical.  That leaves mechanical failure.

I thought I broke my winch's clutch lever but it looks fine on the inside.  I did a quick tear-down of the gear-side of the winch tonight and everything appears to be in order.  Nothing that I can see appears to be snapped, broken or stripped.  I'm going to clean all the grease off everything tomorrow and give it a really good looking over, but anyone have any thoughts on what I should be looking for?

I had one thought, the big gear that goes around the outside of the planetary gears (sliding ring gear).  How does it go from being engaged, to moving to free-spool?  The clutch lever appears to work by having one side that sits flush to the housing, and one side that's rounded and locks the ring gear in place against the housing.  I was pretty sure before I took it apart that the clutch lever was turning all the way, but given how simplistic it seems now I'm not so sure....  Everything inside was spin-able by hand from the drum.

Could it still be an electrical issue?  If so, what should I be looking for when I take the solenoid box apart?

[sn4cktime]

So, got everything back together today after fixing the clutch lever inside.  Checked solenoid with meter.  All seemed good.  Powered it in and out a few times (no line, just the drum) and flicked the clutch in and out a few times.  So I thought I'd run it for a bit before spooling the line.  After about 20 seconds smelled electrical burning and stopped.  A puff of smoke squeaked around the drum from the motor side of the housing.  Gave it a minute and tried controls.  Solenoid clicked a few times but the motor did nothing.  Pretty sure it burned out.  Then even the solenoid stopped.

So, I've had enough of this thing.  Ripped it all out, and tossed it.

Going to buy a Warn and get the cordless control module (like the one Dom has).  Haven't decided if I want to go with the 9.5ti (temp control would be pointless on the remote) or the 9.5si (no solenoid to go bad) or get a heavier model in the 12000lb range.  My rig is pretty heavy with all the steel I've added to it, but pretty sure I don't need that size of winch yet.

Do a quick weight tab here in lbs:
-2 door JK = 3760
-skidplates = 85 + 70 + 20 = 175
-sliders = 55 x 2 = 110
-fenders = 45 x 4 = 180
-front bumper = 70
-rear bumper = 135
-spare tire = 110
-winch = 100

So that'd be 4640 lbs approximately.  I read a winch should always have a rating of at least 2x that of the vehicles weight.  So still good.   

Anybody using the ti or si.  Good bad?  Easy to rebuild?

[w squared]

Warn = good 

I'm very happy with my 9.5ti. I've seen some folks do crazy things to Warn winches in the past (amazing what seems like a good idea when you didn't pay for any of the hardware), and they just seem to keep going.

12,000 pound winch is probably overkill on your rig (or mine). If you had a FSJ, maybe. When you're thinking about winch rating vs. vehicle weights, consider these rule-of-thumb number that the US army uses:

-Stuck to the top of the tires means you need a pull force equal to the vehicle's weight

-Stuck to the hubs means you need a pull force equal to twice the vehicle's weight

-Stuck to the bottom of the body means you need a pull force equal to three times the vehicle's weight

After you add yourself, a full tank of fuel, a buddy to help with your winch cable, and a cooler of Bacon to bribe Dom with so that he'll pull you out...5000 pounds.

Then again, you carry a snatch block, right? That will allow you to double your winch's 9500 pound pull.

[SwampSinger]

my warn is rated for 9000lbs and my Jeep (Bacon bribe included) weights 5023lbs fully loaded with tools and parts....

I would recommend taking the time to set up a snatch block for hard pulls ... it will help your poor little winch.

I had a MX8000 before (old winch... same as M8000) and it finally died on my after a long ,,,,... very long pull ( I had to hook up my 100ft line 3 times) .... that winch is like  Frankenstein... I sold it to TJ (XJHERO's roomate) he changed a part of the casing that was cracked and she was alive again

I agree WARN = GOOD

[JackstandJohnny]

2x the weight of your vehicle is more than enough.  i've read/heard 1.5x is satisfactory.  i used to have a xd9000i on the ford and trust me, that thing was put to use.  same with a buddies m8000 on his ford, and it still resides at the front of his blazer........ and 8k winch is more than enough on a jeep.  i woudln't even bother with a snatch block unless you were buried in skeg up to the doors and had about 20' of cable spooled out...........
just going from experience. when u wheel a fullsize truck on 33s (as i did for so many years) you get used to the winch cable!

[sn4cktime]

Thanks for the opinions.  Got a 9.5si on the way.  Should have it in my hands by the weekend.

Where did you put the wireless control box again Dom?  I recall it being up near your firewall right?

[SwampSinger]

Thanks for the opinions.  Got a 9.5si on the way.  Should have it in my hands by the weekend.

Where did you put the wireless control box again Dom?  I recall it being up near your firewall right?

Yep.... high up on the firewall

[w squared]

2x the weight of your vehicle is more than enough.  i've read/heard 1.5x is satisfactory.  i used to have a xd9000i on the ford and trust me, that thing was put to use.  same with a buddies m8000 on his ford, and it still resides at the front of his blazer........ and 8k winch is more than enough on a jeep.  i woudln't even bother with a snatch block unless you were buried in skeg up to the doors and had about 20' of cable spooled out...........
just going from experience. when u wheel a fullsize truck on 33s (as i did for so many years) you get used to the winch cable!

Don't forget...snatch blocks are for more than just mechanical advantage. With some trees you can use them for re-directs too 

[sn4cktime]

Yeah, been thinking I should nab one or two for ACE.

Anybody know who splices synthetic winch line?  I've got the line from my old winch and figured I could make a line extension or two out of it.

Also, cheapest place to grab a couple tree saver straps (around the 5-10' length) to use for said snatch block.

[tubby]

Try Titan Supply here in Calgary or Unirope in Edmonton for your winch line splicing.
Cheap tree savers straps? Princess Auto has them for uber cheap.

[WhiteOut]

Shaw Industries has the tree savers cheap, I think I paid $16 for mine.  I'll send you their number and addy.

[SwampSinger]

Also, cheapest place to grab a couple tree saver straps (around the 5-10' length) to use for said snatch block.

Modern,... they have 10' and 20'.... and they are a CJA supporter  ... what did we get from Shaw Industries at the S&S again? 

[w squared]

Yeah, been thinking I should nab one or two for ACE.

Anybody know who splices synthetic winch line?  I've got the line from my old winch and figured I could make a line extension or two out of it.

Also, cheapest place to grab a couple tree saver straps (around the 5-10' length) to use for said snatch block.

If you're running synthetic line, you can splice it yourself.

End-for-end splice:
http://www.samsonrope.com/site_files/12S_C2_EndEnd.pdf

Eye splice:
http://www.samsonrope.com/site_files/Class_2_12-Strand,_Eye_Splice.pdf

If you're patient and careful, those plice instructions will let you do it all yourself. I spliced the thimble into my own synthetic winch line, and so far so good 

[sn4cktime]

...I spliced the thimble into my own synthetic winch line, and so far so good 

Yeah, I saw it on there.  It looks good.  Beats a hook.

I'll have to take a good look at those splicing instructions... not something I'd want to screw up.

[w squared]

They're not quite as hard as they look. Read them through once or twice, then again with the rope in your hands (kinda pulling and pushing and testing), then take a run at it.

Make sure that you have lots of time, good lighting, a confortable chair...and NO CATS IN THE AREA.

You don't want to know how I found out why that last point is so important.