Suggestions for warn winch maintenance

[summerprophet]

So went up in the mountains today to walk the dogs (actually it was to get out of the fog that is blanketing the valley where we live), and along the way we punched through the snow.

To make a long story short, winch didn't work, field repaired it, got out, had a nice stroll, and got home safe and sound.

What to do now: (and this is where I am needing advice):
1. Clean up the corrosion, seal the box better, call it good
2. Swap out the solenoids, I am not sure if need to be concerned about corrosion inside the cylinders
3. Swap out the entire housing with a new one from warn.
4. Other?

 

[1911]

I would try cleaning the buss bars and terminals for sure; no way to tell from here if the bottom (or other) solenoids might be bad too, you'll have to test each one individually.

If you end up having to replace some solenoids, you might consider replacing them all with a single Albright contactor, which is sealed against the elements.

 

[Antichrist]

Clean up everything well. Consider replacing the cables, at least the black one that runs under the F2 marking. The gap between the lug and insulation will let it corrode. Should have adhesive lined heat shrink on them.
When you reinstall liberally coat all electrical connections with dielectric grease during and after assembly.
I usually replace nuts and washers with brass.

 

[I Leak Oil]

After you do some of the above, get a cover and cover it when not being used. Use the winch once a month. They don't like sitting. Not sure what model you have but most aren't "water proof" so buying a new housing may not solve any moisture issues.

 

[soonenough]

Many of the newer Warn winches come with contactor controls instead of solenoids, which eliminate moving mechanical parts and hence several methods of failure. I'm sure you can buy the parts from Warn to convert it to a solid-state controller.

Here's a writeup of a guy that used a Superwinch contactor to replace the solenoids on his Warn winch: http://www.fjcruiserforums.com/forums/4x4-off-road-tech/130031-warn-winch-upgrade.html

 

[java]

Many of the newer Warn winches come with contactor controls instead of solenoids, which eliminate moving mechanical parts and hence several methods of failure. I'm sure you can buy the parts from Warn to convert it to a solid-state controller.

Here's a writeup of a guy that used a Superwinch contactor to replace the solenoids on his Warn winch: http://www.fjcruiserforums.com/forums/4x4-off-road-tech/130031-warn-winch-upgrade.html

Exactly what I was going to suggest. Allbright solenoid. Summit Racing carries the Superwinch replacement ones.

 

[TACTICALJEEP]

exactly what Anticrist said. They sell the heat shrink, cable etc, at carquest. I made my own cables, terminals, heatshrink etc for less than 60.00$ a couple weeks ago

 

[1911]

Many of the newer Warn winches come with contactor controls instead of solenoids, which eliminate moving mechanical parts and hence several methods of failure. I'm sure you can buy the parts from Warn to convert it to a solid-state controller.

Here's a writeup of a guy that used a Superwinch contactor to replace the solenoids on his Warn winch: http://www.fjcruiserforums.com/forums/4x4-off-road-tech/130031-warn-winch-upgrade.html

Well yeah, that is my write-up - why I suggested it in post #2. Can also find it in the Winch section of IH8MUD.

 

[Stumpalump]

Clean the connector with the big red power lead and tighten and spray the rest with WD 40. You can get a solenoid from autozone if you think you need a spare but a couple of spring loaded clamps or jumper cables can jump across the solenoids to get you out of a jam.

 

[soonenough]

Well yeah, that is my write-up - why I suggested it in post #2.

Whoops, I didn't see that you'd already mentioned it. It's a great write-up, that's why I linked it :sombrero:

 

[Sirocco]

Another vote for an Albright. Fit and forget!

G

 

[Antichrist]

Many of the newer Warn winches come with contactor controls instead of solenoids, which eliminate moving mechanical parts and hence several methods of failure.

If you're talking about Albright solenoids, they have moving parts.

 

[1911]

Whoops, I didn't see that you'd already mentioned it. It's a great write-up, that's why I linked it :sombrero:

No problem; thanks for providing the link, which I was too lazy to find.

 

[summerprophet]

Thanks to everyone for your help.

Came to the conclusion, I would just clean all the terminals with a wire brush, and replace the end fittings.

Well….. I snapped the corroded Solenoid post off when I was trying to get the nut off.

Now I have a contactor in the mail.

Edit:
Installed per 1911's write up linked above. Works like a charm. Thanks guys.