I just finished fixing my winch that made a clicking noise in both directions but didn't operate. I thought I'd write up what I went through in the hopes that it may help someone else do it faster. I found some help here, on the Warn site, and on a J**P site.
If you can hear a click but your motor doesn't operate (in one direction or both), it is likely one of three things. Cables or connections, the motor itself, or one or more solenoids.
Start with the cheapest and simplest- checking the cables visually and cleaning up the ends. I also tried jumping from the ground lug under the motor back to the battery ground with jumper cables.
To test the motor, use the following procedure from WARN:
If you can hear a click but your motor doesn't operate (in one direction or both), it is likely one of three things. Cables or connections, the motor itself, or one or more solenoids.
Start with the cheapest and simplest- checking the cables visually and cleaning up the ends. I also tried jumping from the ground lug under the motor back to the battery ground with jumper cables.
To test the motor, use the following procedure from WARN:
Warn Motor Testing Procedure
If you find yourself in a situation where your winch is clicking but it is not working, you may have a motor problem....or you may have a solenoid problem. The following procedure, from Warn, will help you determine the status of your winch motor.
1. Put the winch in freespool.
2. Disconnect the positive lead from the battery (leave the ground lead attached).
3. Label and disconnect the three cables that run from the control pack to the three posts on the motor.
4. Stamped next to the three posts on the motor will be "A", "F1" and "F2". Run a small jumper wire (5"-6" dead lead, 8 ga. will work just fine) from "A" to "F1" and put power from the battery (jumper cables work good) to "F2". The winch motor should run in one direction at this time.
5. Next, place the jumper wire from "A" to "F2" and put power from the battery to "F1". The winch motor should run in the opposite direction at this time.[FONT=verdana, arial, helvetica]
[/FONT]If these steps are followed correctly and the motor runs in both directions, the motor is good.
(*Note: if you have a set of modern jumper cables that have side mount type clamp ends, you can use it to jump from F1 and F2 to A. Otherwise you're going to have to make or buy an 8 ga. short jumper. Note also that when you make the final connection you will get a BIG spark. I expected it and still was surprised.)
If the cables and the motor are good, chances are that one or more solenoids are gone. You can spend the time to test them one by one to see which one or two are bad, but you don't want to have to do this more than once. Buy 4 of them and replace them all. I got 4 72631 Warn brand solenoids for $75. shipped.
To remove the solenoid cover, remove the top two allen head screws and loosen the bottom two a few turns each. The cover should pop off. Take a picture and draw a diagram of the wiring that you see. See below.
Disconnect the Plus wire at the battery. Start by removing the control wires (smaller gauge)-once they are out of the way it's easier to remove the big wires and copper jumpers. The solenoids should come out easily with a twist and a lift, starting with an end one.
Replace them all and replace the wires and jumpers per your diagram.
2. Disconnect the positive lead from the battery (leave the ground lead attached).
3. Label and disconnect the three cables that run from the control pack to the three posts on the motor.
4. Stamped next to the three posts on the motor will be "A", "F1" and "F2". Run a small jumper wire (5"-6" dead lead, 8 ga. will work just fine) from "A" to "F1" and put power from the battery (jumper cables work good) to "F2". The winch motor should run in one direction at this time.
5. Next, place the jumper wire from "A" to "F2" and put power from the battery to "F1". The winch motor should run in the opposite direction at this time.[FONT=verdana, arial, helvetica]
[/FONT]If these steps are followed correctly and the motor runs in both directions, the motor is good.
(*Note: if you have a set of modern jumper cables that have side mount type clamp ends, you can use it to jump from F1 and F2 to A. Otherwise you're going to have to make or buy an 8 ga. short jumper. Note also that when you make the final connection you will get a BIG spark. I expected it and still was surprised.)
If the cables and the motor are good, chances are that one or more solenoids are gone. You can spend the time to test them one by one to see which one or two are bad, but you don't want to have to do this more than once. Buy 4 of them and replace them all. I got 4 72631 Warn brand solenoids for $75. shipped.
To remove the solenoid cover, remove the top two allen head screws and loosen the bottom two a few turns each. The cover should pop off. Take a picture and draw a diagram of the wiring that you see. See below.
Disconnect the Plus wire at the battery. Start by removing the control wires (smaller gauge)-once they are out of the way it's easier to remove the big wires and copper jumpers. The solenoids should come out easily with a twist and a lift, starting with an end one.
Replace them all and replace the wires and jumpers per your diagram.