Outer Limits 4x4 Board

hey all


im having a bit of trouble with my warn winch. when i try to wind out the cable the motor engages and works fine, but when i go to wind the winch in, the solanoid just clicks in the main power box and the motor won't start.

i've just bought the car and i've never had a winch before. no instruction manual came with it either.

any help would be appreciated

You will need to replace 2 of the 4 solonoids in the control box, test light which one are not contacting

solenoids

any idea wat may have cause the problem

antpoo69 wrote:any idea wat may have cause the problem

Vibration or from hitting roos. i ended up rubber mounting mine in the engine bay and it seemed to fix the problem

awesome i'll see how i go.
thanks for the info

Give the solenoid body a 'rap" when operating.
Sometimes moisture makes the centre shaft bind.

Bazzle

now if it isnt working in either direction and makes a little click sound.... all 4 solenoids?

problem solved!!!

it was one solanoid. cost me $28 and it's all fixed.
thanks for all the info.

Then for another $56 you can parrallel the winch IN circuit and multiply the reliability by 10, with the two extra solenoids.

Remember your warn winch pulls 460 odd amps at full load, which is not shared between the two solenoids. It sort of goes in a figure 8 (power to field 2, short armature to field one) so that's 460 amps thru each solenoid that is rated at 100 amps continuous! No wonder warn don't warrant the solenoids....

I've changed mine to six solenoids and done a few others and since then never stuffed one (touch wood).

Hope that gives food for thought...

DIRTY ROCK STAR wrote:now if it isnt working in either direction and makes a little click sound.... all 4 solenoids?

The click is the solenoids working...although they may not be swiitching

could be anything tony, get onto it with a multi meter and see if they are switching, or drop if off and return my bender and ill have a look for you

Leeroy wrote:Then for another $56 you can parrallel the winch IN circuit and multiply the reliability by 10, with the two extra solenoids.

Remember your warn winch pulls 460 odd amps at full load, which is not shared between the two solenoids. It sort of goes in a figure 8 (power to field 2, short armature to field one) so that's 460 amps thru each solenoid that is rated at 100 amps continuous! No wonder warn don't warrant the solenoids....

I've changed mine to six solenoids and done a few others and since then never stuffed one (touch wood).

Hope that gives food for thought...

got a wiring diagram? too lazy/stoopid to work it out sorry.

Sorry I'm WAY too stoopid (ie computer illiterate) to make a picture go on a website... I'll try to explain it, if no good pm me I'll draw it up and get my missus to scan it and email it to you or something.


Ok mount two solenoids where ever you see fit (shorter the cable distance the better). On one of them, attach a cable from one of the large terminals to the positive battery terminal (at least 2B&S). Connect the other large terminal (2B&S cable again) to F2 on your winch motor.

With the other solenoid, attach a 2B&S cable from one terminal to F1, and the other goes to the armature (A).

Ok now the two small terminals; on each solenoid earth one of the small terminals to a good earth. Wire the other one (4mm is fine) to either of the two small terminals in the normal solenoid box that has the GREEN wire attached to it. Green is the winch-in positive.

This will work on both the older style (3 wires in remote plug) and the newer (5 wires) warns.

As a bonus doing this cuts the volt loss at full load by about a quarter of a volt; improving power and minimising heat build up to a small degree.

Hope that all makes sense.

Leeroy wrote:Sorry I'm WAY too stoopid (ie computer illiterate) to make a picture go on a website... I'll try to explain it, if no good pm me I'll draw it up and get my missus to scan it and email it to you or something.


Ok mount two solenoids where ever you see fit (shorter the cable distance the better). On one of them, attach a cable from one of the large terminals to the positive battery terminal (at least 2B&S). Connect the other large terminal (2B&S cable again) to F2 on your winch motor.

With the other solenoid, attach a 2B&S cable from one terminal to F1, and the other goes to the armature (A).

Ok now the two small terminals; on each solenoid earth one of the small terminals to a good earth. Wire the other one (4mm is fine) to either of the two small terminals in the normal solenoid box that has the GREEN wire attached to it. Green is the winch-in positive.

This will work on both the older style (3 wires in remote plug) and the newer (5 wires) warns.

As a bonus doing this cuts the volt loss at full load by about a quarter of a volt; improving power and minimising heat build up to a small degree.

Hope that all makes sense.

Draw it (BOLD), scan n send it to someone who can post it here....