Aisin 80 series factory doesn't got out under load.

[shromani]

'90 HDJ81 factory winch being temperamental and needing some TLC. when under load, I am unable to release the load on the line to reposition my pull. It will when under no load, but no joy with a reasonable amount of tension. no clicking just silence? Is this a relay or my gears binding? Thoughts?

Also I dont seem to get a strong pull, definately no where near 8000# before it stalls. I have new NAPA batteries. Wondering if there's a known bad connection issue or something easy, before I have to yank and bench it.

 

[Greg_B]

I don't have one, but recall @Glenn-BJ74 asking the same thing. If you find a work-around or solution from your bench work the tech would be good.

hth's
gb

 

[IanB]

I had the same issue last year, found the relay was badly corroded (in the passenger side wheelwell, bolted inside the splash guard in front of the tire). @asutherland had found a locally available replacement, which I got and installed, but I haven't gotten the winch back in due to some other complications to test the fix yet.

Symptoms were the same, it appeared to work till it got a load on it, then nothing.

 

[asutherland]

What Ian said. Mine was totally bunged. Also make sure your ground points are all clean and well connected. I found one of my main engine grounds loose. (on the old truck)

 

[IanB]

What Ian said. Mine was totally bunged. Also make sure your ground points are all clean and well connected. I found one of my main engine grounds loose. (on the old truck)

Can you find the link to the thread with the replacement relay info? I came up empty when I searched earlier.

 

[shromani]

This is great info, some leads to follow up on. I'll check those relays in the fender and all my ground points could use a good cleaning.

Thanks

 

[asutherland]

Theres just one big relay in the fender, it controls main power to the winch. Make sure to especially check the ground of the winch, it's a short cable that runs about a foot - from the winch to the front of the left side frame rail. Because of its location I could see it getting dirty or loose.

I believe the power for the winch comes off one of the leads on the 24/12 switching solenoid near the fuse block. It goes through the big solenoid below rhe left side battery bòx and then to the winch .

 

[shromani]

Good to know. I have a side question. Does the winch pull from both batteries, in parallel, to get that extra current, or from just one?

 

[MUDZLLA]

Good to know. I have a side question. Does the winch pull from both batteries, in parallel, to get that extra current, or from just one?

Both, but the winch power cable is on the wrong side of the switchover relay because alternator plus battery 1 goes through the relay for no reason. It will burn out the relay under heavy winching.