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Thread: Winch Failure

  1. #1

    Default Winch Failure

    I was hauling a load of firewood with my AC-500 and trailer. I needed to come out of a steep gully to get back up to the trail. I decided to use the winch and low range to come out safely. So I hooked up to a nice tree and started up nice and smooth. I was 3/4 of the way up when the winch released and I had to back down. You can pull cable by hand even in lock and it will not wind up Even with no load. It will go in reverse though. The winch is a Warn 2.5 model. Any one else have a problem with this model? It was only the second time I used it. I may have been close to the limits, but it did not stall it just stopped pulling. I will call Warn next week to see if it can be repaired.

  2. #2

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    I've disasembled a couple of warn's but those were easy fixes. I'm by no means a winch guru but I'm willing to bet you stripped out one of the plastic gears.

  3. #3
    Member AKDoug's Avatar
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    Default

    I have Warn 2.5's on both of my AC's..they came with them. I have worked the snot out of both of them and have never had an issue at all with them. I have no idea if they are a good winch, but they've worked for me so far.
    Bunny Boots and Bearcats: Utility Sled Mayhem

  4. #4
    Member KenaiJay's Avatar
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    Default ?

    The free spool release is locked up on my warn...Any idears on how to loosen it?

  5. #5

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    Quote Originally Posted by Water_Gremlin View Post
    I've disasembled a couple of warn's but those were easy fixes. I'm by no means a winch guru but I'm willing to bet you stripped out one of the plastic gears.
    You are right, must be a gear failure. I am sr
    orry to hear they are plastic, but not surprised. I will contact Warn and order the parts needed. It had a one year warrenty and it is two years old. It may have 5 miniutes of use in the last two years. I have the same winch on my 400 and used it alot with no problems.

  6. #6
    Member TWB's Avatar
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    Default

    An issue I had with my 4K was packing mud behind the engage/free spool switch, so it wouldn't fully engage and this happened out in Eureka in a swamp an I was burried pretty bad.

    Try pulling that off and see if its clean. I applied some marine grease liberally to keep the junk out.
    We do not go to the green woods and crystal waters to rough it, we go to smooth it. We get it rough enough at home; in towns and cities; in shops, offices, stores, banks anywhere that we may be placed

  7. #7

    Default

    I recommend going in trailercraft in anchorage, as they are the warn distributor. They sold me the very part you need for $28 a couple months ago. They keep these parts in stock.

  8. #8
    Member Crumm's Avatar
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    Default

    Warn winches are very easy to disassemble and repair. Click here for part numbers and exploded view.

    If Trailer Craft doesn't have the part in stock try Six States. They were the only one in the State that had some Warn parts I needed last summer.

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  9. #9

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    Thanks for the advice. I'll try Trailer Craft for any needed parts. We use to have one in Fairbanks but they closed and now we only have 6 Robblies. It is nice to have support for a product locally. That is the problem with some of the chineese copies, you have to send away for parts ect. thanks again

  10. #10
    Member Crumm's Avatar
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    Quote Originally Posted by Diggerdik View Post
    We use to have one in Fairbanks
    I am also in Fairbanks. Six States shipped me Warn parts and I had them in two days via USPS.

  11. #11

    Default

    I don't want to hi-jack the thread but since were talking Warn winches does any body have a reason why I would keep breaking the winch cable? I have a 50 inch Moose plow on my Grizzly and the only apparent function of the winch cable is to lift the plow. The first time it broke 1 inch to the winch side of the factory crimped splice that holds the hook on. I fixed it with two 3/16 th u clamps made for the purpose. The cable has broken two more times a inch or two from the clamps and once in the loop that goes around the hook.

    I have never payed out the cable more than the few feet needed to attach to the plow yet the second to the last time that I repaired it I payed out enough so I could run it under the door into the garage so I could fix it next to a warm stove. After repairing it I hit the "in" button with one had and held the cable in the other hand letting slide through my gloved hand with some tension so as to wind it up tight on the winch. At this time I notice that the cable had several splinters sticking out of it that were catching on my leather glove. Examination revealed that it was frayed for about 10 feet. So I payed it back out until I got to cable that wasn't frayed and started over. Several hours of more plowing and it broke again and once again several feet of the cable are frayed even though I've never unwound more that a foot or so.

    Any suggestions? Keep in mind that the plow and winch are both brand new!

  12. #12
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    Default Elmerkeithclone

    It sounds like you are running the winch cable in too far. As soon as the plow is fully raised let off the "in" toggle on your winch control. I did this once on a knuckle boom on a commercial fishing boat with expensive everything and one very mad skipper.

  13. #13

    Default

    Just get a synthetic cable and be over with it. Snow plows and standard cable don't mix well because of kinks. The rope works best with the plow. Also a lot safer for regular use.

  14. #14

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    Thanks stratofisher. Thats exactly what I'll do!

  15. #15
    Member ARGONUT's Avatar
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    Default

    don't waste the money on the rope for just plowing just use 10 ft. of quarter inch rope for ploiwing and get the expensive plasma line for real winching. i spent the money on the plasma line to plow with and use to really work the winch and regretted plowing with the expensive stuff. the constant in and out of plowing over such a short run of the cable"rope" causes undo wear and when you go to really use it you ahve a great chance of breaking it and havin to retie it any way save the time save the money and use regualr old rope for lifting your plow and save the good stuff for when your stuck.

  16. #16

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    Quote Originally Posted by ARGONUT View Post
    don't waste the money on the rope for just plowing just use 10 ft. of quarter inch rope for ploiwing and get the expensive plasma line for real winching. i spent the money on the plasma line to plow with and use to really work the winch and regretted plowing with the expensive stuff. the constant in and out of plowing over such a short run of the cable"rope" causes undo wear and when you go to really use it you ahve a great chance of breaking it and havin to retie it any way save the time save the money and use regualr old rope for lifting your plow and save the good stuff for when your stuck.
    Plasma line is excellent for winching. And good for snow plow lifting in some way.

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