Jeep TJ Winch Thoughts

[computeruser]

I just finished installing a new Warn M8000 (minus electrical) today, after removing the Ramsey REP8000 that I've had for the past couple years and repainting the mount plate yesterday.

Unlike the Ramsey, it is not possible to mount the solenoids on top of the winch motor on the Warn. This is probably for the best, since the Michigan weather didn't do my Ramsey's solenoids any favors. In hindsight I should have just purchased a winch with integrated solenoids and saved myself a lot of aggrivation, but, well, the false economy of the M8000 got the better of me. So I need to mount the solenoids somewhere else. I'm thinking about putting them above the battery, mounting an L-bracket to the battery hold-down and attaching the solenoid unit to that bracket.

The only problem with this idea is that I'm thinking seriously about doing a dual-battery setup shortly, particularly the Mean Green one that has two Optima-type batteries mounted on their side, one above the other, so I don't have to have my A/C lines rerouted. I don't know if this setup will allow the solenoid assembly to remain up around the batteries or not, but I don't think so. I'd hate to spend $$$ on a bunch of 2-ga wire and then have to re-do it a few months or a year down the road, so I'd like to get it right the first time.

Any thoughts on where else to mount the solenoids on a TJ? I could possibly mount them next to the power brake booster, or maybe up front on the driver's side if I relocate the horn.

Also, any thoughts on why not to use the hole in my mount plate as a place to install the winch controller plug-in? I'll probably install in-cab controls, too. I thought about leaving the controller plug-in on the solenoid box, but would prefer not to have to pop my hood to winch. Any thoughts on this?

I should also add that I had to re-drill the roller fairlead mounting holes and ream out the holes on my mount plate, and may still have to pull it and grind some metal off the plate behind the lower roller. Suffice it to say, there is clearly a value to buying things that are designed to work together as part of a system - using Warn's mount, for example, would have saved me this irritation, and an integrated solenoid winch would not have required monkeying around with wiring - and the whole setup would have been completely installed and working already. Lesson learned, I suppose.

 

[ntsqd]

My first thot is that nothing ever fits together, bolts together, or works together as intended. It would be nice if they did, but it would be insane to ask any given mfg to allow for every permutation and combination possible using their parts in a larger system.

Second thot is that the integral relay winches interfer more with radiator airflow. Whether it's enough to cause problems would depend on the individual vehicle. In any case, they are not my preference for this reason and the solenoid servicability reason.

Third thot is the rumbles I've read of miscreants causing vehicle damage with the winch. Whether that is internet rumor, urban legend, chicken little running around, or something that has actually happened it seems prudent to not offer the easy option.

Fourth is that Warn went to a 5 wire relay control scheme with the integrals, not sure about the remotes. They claim it's a safety thing. I suspect it's to make it impossible to use the Ramsey Remote Control system (which they warn against) and possibly to make point No. 3 more difficult.

If you understand controlling relays you can work around the 5 wire system, but if you do I strongly suggest that you change the plug and the socket(s) to not be compatible with Warn. I've used 4 pin trailer connectors, but they are not all that great. Next go-round I may just use a Weatherpack and also build a blanking-off plug.

W/o standing there it looks to me like the relay pack could be mounted to a sturdy bracket next to the air filter's baffle, possibly even using the OE filter box's mounting holes.

I would not face a control socket up. Too easy to fill with water or dirt. My only current vehicle with a winch (ironically a ~1700lbs glass buggy) has one control socket only, and it's in the dash. The 20' self-coiling remote cord is long enough to reach either end of the vehicle.

 

[tjbliley]

First, for safety you should winch with the hood up to allow the motor more air flow and the add another layer of protection between you and the cable.

Second, You could make a bracke the will hang from u-bolts from the core support bar running from the firewall to the radiator. It would suspend the control overtop of the A/C lines.

Third, they do make a bracket to mount the solinoid on top of the motor of that winch. I have been running that same setup for three years. bracket works well but it is still out in the weather.

http://warn.iwebcat.com/_Members/lookups/partdetail.asp?hdnPN=282945&hdnSts=0&hdnUK=27558&hdnCAT=418&hdnQ=1&hdnLK=661&hdnLT=3&hdnSW=10870&hdnOEM=0&hdnUniv=1&hdnAPFlag=&hdnWN=1&

 

[computeruser]

First, for safety you should winch with the hood up to allow the motor more air flow and the add another layer of protection between you and the cable.

True. I was thinking more of winching in low-lbs utility mode rather than recovery mode, though my post didn't offer any hint of it. I never pulled a single vehicle with my previous winch, but tensioned hazard trees and trees with a back-lean lots of times when doing residential removals. Not a lot of concern about overheating or, injury to persons sitting the vehicle when doing that sort of winching.

Second, You could make a bracke the will hang from u-bolts from the core support bar running from the firewall to the radiator. It would suspend the control overtop of the A/C lines.

Hmmm. I hadn't thought of that as much as I probably should have. Since I haven't had time to mount the solenoids yet, I'll give that idea some thought.

Third, they do make a bracket to mount the solinoid on top of the motor of that winch. I have been running that same setup for three years. bracket works well but it is still out in the weather.

I thought about that. But since the weather + road salt here in MI is not favorable to solenoids, I figure I'll give underhood mounting a shot this time. The solenoid housing just doesn't seem like it would be adequately watertight in the long run, even with some silicone caulk and some sort of vent hose setup. Plus, I just went out and bought a whole bunch of welding cable...gotta use it for something, ya know!


Anyway, pics will follow when finally have time to get this completed.

 

[computeruser]

OK, I did a quick install today. I mounted the solenoid on an L-bracket in the area immediately above and forward of the battery. I had two cable clamps hanging around that I salvaged to serve as u-bolts, with nylocks instead of the usual nuts that come on cable clamps.

Electrical to the winch is 60" 2ga welding cable, and the + wire from the battery to the solenoid assembly is one of the 12" 2ga leads that Warn originally intended would run from their solenoid to the winch itself.

I suspect that this mounting method should work well for now, until I go with a second battery. Even then it might be possible to tweak the mounting system a bit and not have to rewire anything except the 12" + lead.

 

[tjbliley]

Looks good, are you going to also add an interior set of controls so you don't have to pop the hood every time you use it? I think with that one you can use a 4-round extension setup to remote mount the plug off the solenoid box.

 

[computeruser]

Looks good, are you going to also add an interior set of controls so you don't have to pop the hood every time you use it? I think with that one you can use a 4-round extension setup to remote mount the plug off the solenoid box.

Yeah, I'll hardwire to the interior one of these days. I've got some interior wiring tasks to handle when I have a spare day to play around (hardwire my air compressor, inverter, and trailer winch power setup), so I'll tackle it at that point. But I've got some other irons in the fire in terms of outdoor power equipment purchases and rebuilds, so I think that vehicle upgrades are going to have to wait for the fall...

If only money grew on trees...