Aisin 80 series factory winch rebuild (1 Viewer)

[asutherland]

Hey all,

Does anyone have any write-ups and/or photos on doing an overhaul on a HDJ81 factory winch? Mine has been acting up lately - grinding, not pulling very strong, I expect the worst but am hoping for the best.

That being said, does anyone have the winch pages of the FSM? My (US) FSM doesn't mention it at all.

thanks,
Andrew

 

[finderscuba]

Here you go - mechanical (PTO) and electric: https://www.dropbox.com/s/quik8mf1vp7h9v6/fj_hdj_hzj-80_series_winch.pdf

 

[asutherland]

Right on, thanks dude.

 

[asutherland]

Update:

I removed the 200 lbs beast of a bumper, removed the winch from inside the bumper and started checking things out.

I drained the 0.9L ATF Type F oil from the oil drain hole on the planetary gear side, the ATF looked brand new, no particulates or dis-colouring.. nice and red. Side note.. the gears appear to be perfect, I was able to use two fingers to spin the entire drum (with wire on it)

I took the solenoid pack apart, removed both in/out solenoids (Toyota calls them "Magnet switches"), and checked them according to the FSM checks... both worked fine. I took apart the yoke and armature, everything was clean and dry inside and the armature and bearing spun freely.

I then checked the "Magnet switch #1" - which I should have done FIRST before even removing the bumper and winch.

It's a solenoid used to control main power to the winch, and it's located UNDER the passenger side (left hand side) battery tray. Clearly, it had issues.

On first glance I assumed it needed replacement. But I checked it anyway. No continuity no matter what state the solenoid was in. Now to find a replacement one... http://www.colehersee.com/home/item/cat/189/24812-01/

 

[Tapage]

pretty much appreciated this write up .. I just delete this solenoid ..

 

[asutherland]

Here's an interesting fact... the FSM (link posted above) shows the wire coming off the bottom of the drum, similar to WARN... but mine comes off the top???

 

[asutherland]

pretty much appreciated this write up .. I just delete this solenoid ..

Hmm, interesting. Did you just put a bolt through the two hoop connectors on the thick gauge wiring? Is it a concern having live voltage fairly low on the truck for water crossings etc?

 

[asutherland]

The P+R Western Star has some in stock, they are 180 amp continuous duty 12V. Should that suffice?

 

[Douglas S]

180 amps seems low, but I'm not sure how many amps these winches pull.

 

[asutherland]

180 amps seems low, but I'm not sure how many amps these winches pull.

That's what I was thinking. This one is likely a better option: http://www.colehersee.com/home/item/cat/189/24812-01/

 

[lowenbrau]

Full pull might be more like 500 amps. I'd look at something like this...

http://www.ebay.com/itm/DC-Power-So...Parts_Accessories&hash=item4cfceec241&vxp=mtr

<EDIT>... Forget that one, it is only 100amp rated <EDIT>

 

[asutherland]

FWIW I believe the original part number is 38630‑60130.

http://www.toyodiy.com/parts/p_J_1994_TOYOTA_LAND+CRUISER_HDJ81V-RNMEX_3802.2.html

 

[asutherland]

This is interesting. If this is the case, then the Cole Hersee one I posted would be just fine.

This article from the Overland Journal has some interesting real-world measurements of actual current drawn (maximum at start-up as well as average during a pull) by five different common winches, including a 12K winch: Tug of War: The Ultimate 12v Winch Test

Between the five winches, the maximum draw (start-up spike) ranged from 460 to 769 amps, and the average current draw during the pull ranged from 133 to 165 amps.

https://forum.ih8mud.com/winching-recovery/581291-cut-off-switch-installed.html
http://www.expeditionportal.com/res...40-tug-of-war-the-ultimate-12v-winch-test.pdf

 

[Tapage]

Hmm, interesting. Did you just put a bolt through the two hoop connectors on the thick gauge wiring? Is it a concern having live voltage fairly low on the truck for water crossings etc?

never had chance to cross river that deep with my 80 ( didn't look for that too ) but so far not an issue ...

 

[asutherland]

Well, after checking several parts stores around town, the soonest I could get one of these Cole Hersee ones was 2 weeks. Then I was walking by a JB Auto with my daughter this morning, that happens to be nearly across the street from my house, stopped in on a chance they might have one and they did! Only one, and it was in that store. What luck!

Brought it home, it appears very well built and is significantly larger than the Denso one. Added bonus: the mounting bracket on it fits the mounting holes from the Denso bracket PERFECTLY!

Cleaned up my connectors some more (the ground to the winch yoke was absolutely disgusting) and bench tested the in/out solenoids. I'll be installing the new solenoid tonight, tidying up the wiring, and trying the winch out to make sure it's all good.

I also have 100 feet of 3/8 synthetic winch line on order, should be here in a couple days.

 

[lowenbrau]

Seems perfect. Given the state of the old one is there anything you can do to better waterproof this one? How about a coating of plastidip?

 

[asutherland]

Seems perfect. Given the state of the old one is there anything you can do to better waterproof this one? How about a coating of plastidip?

I believe this one is hermetically sealed, so it should be good. I guess give it 20 years and we'll see how it holds up

Now, other questions. Being that I'm replacing my winch line with synthetic, what should I do about my fairlead? Should I go with a hawse style? Or aluminum rollers?

 

[asutherland]

I am thinking something like this: http://www.polyperformance.com/shop/Delrin-8-Roller-p-2890.html

My current fairlead will need replacing regardless, it's rollers are all torn up from the metal wire on there currently.

 

[Douglas S]

I run a hawse fairlead with my 8274. It was cheap ($15 IIRC) so I didn't bother replacing my rollers.

You're going to love the synthetic line btw.

 

[Tapage]

it's the aisin winch drum good to work with synthetic rope ?