How to remove your heavy @$$ bullbar

[linuxgod]

This weekend I went to swap my rusty hook on the end of my winch line with a ComeUp boss hook. However my Warn VR12S winch seems to be dead. I cannot get any line to unwind in free spool mode, and while the solenoid clicks I cannot get the winch motor to engage forward or backwards. I suspect one of the 20 or so water crossings I hit on Onion Creek at Cruise Moab got water in the winch and has frozen the motor. Wiring looks good, and it worked back in early April when I unspooled it and checked the line before CM.

So I’m forced with the unenviable task of removing a 125# bullbar with a 75# winch mounted to it in order to access the winch. There aren’t many shops in my area who have time to do this before I leave for Colorado in mid-July, and for various reasons I can go into in a separate post I’d like to get this sorted myself.

For those of you who have removed and installed a steel winch bumper, how did you lift and lower it? The only horizontal “flat” part on mine is where it mounts to the frame horns, which is all of maybe 1/2” thick. Unfortunately the Trail Tailor design doesn’t have a separate winch mounting portion.

I have a floor jack, jack stands, and plenty of 2x4s, but even with my 16 year old assisting I expect this to be unwieldy to maneuver and lower (and raise) safely. Any pro tips, aside from make more friends who like to wrench and will work for beer?

Pic of one of the crossings that probably destroyed it, because every thread needs a photo.

 

[jfz80]

No upper hoop/bar on your bumper?

I’ve used an engine hoist a couple
Times to mount/dismount an arb with winch combo. Tree saver Strap around top bar. Lift to height. Then you only need to manipulate angle to slide in to frame rails.

I’ve done it with a helper before as well just lifting bumper combo up by each end and setting it on top of frame rail angled back to pivot down onto rail. And then wiggle/walk it back on frame horns.

*all based off 80 series experience

 

[linuxgod]

No upper hoop/bar on your bumper?

I’ve used an engine hoist a couple
Times to mount/dismount an arb with winch combo. Tree saver Strap around top bar. Lift to height. Then you only need to manipulate angle to slide in to frame rails.

I’ve done it with a helper before as well just lifting bumper combo up by each end and setting it on top of frame rail angled back to pivot down onto rail. And then wiggle/walk it back on frame horns.

*all based off 80 series experience

It does have a hoop. I don’t have an engine hoist, but I do have ropes and ratchet straps and my garage has rafters…

 

[Sandroad]

I suggest lifting it, or at least supporting it from the rafters as you remove bolts. I think that has the potential to be safer and easier than using jacks and stands from underneath. Perhaps 2 come-a-long type hand winches hanging from rafters, one on each end to allow for easier manipulation for reinstalling. Once unbolted, back the LC away and access the winch. This is one project where I would not be afraid to buy or rent some appropriate tools.

 

[TeCKis300]

Harbor Freight lift table is perfect for this type of work. Stable and adjustable height to help get it placed back also. There's a 500lb and 1k lb version.

Could make a motorcycle lift work too. Or a transmission jack.

 

[Willie G]

FWIW - I like to spread the load on the rafters by hanging the lifting device from a 4x4 laying across several rafters.

I'd use one 4x4 per each lifting device.

 

[kcjaz]

Here’s how I do mine with engine hoist:

The TJM is lite enough one person can pick it up and two people can position it to bolt on. I use the hoist when I solo. The winch is is a separate cradle that is installed before the bumper so you never lift the bumper and winch.

 

[ikarus]

How does the winch mount to your bumper? This may not help, but on my 100 I just installed them separately, alone in my garage late at night because I apparently need more friends

I just lifted the bumper by hand first and installed it, then used ratcheting jackstands to lift the winch into place.

If the winch mounting bolts aren't accessible while the bumper is installed then I agree with the engine hoist or a block and tackle setup rated for the weight. Probably $100-300 and you'd have the right setup for either method.

 

[Ali FJ80]

Did my front and rear with my hydraulic mechanics seats which made it easy to adjust height and roll things around.

 

[linuxgod]

How does the winch mount to your bumper? This may not help, but on my 100 I just installed them separately, alone in my garage late at night because I apparently need more friends

I just lifted the bumper by hand first and installed it, then used ratcheting jackstands to lift the winch into place.

If the winch mounting bolts aren't accessible while the bumper is installed then I agree with the engine hoist or a block and tackle setup rated for the weight. Probably $100-300 and you'd have the right setup for either method.

My Trail Tailor is a one piece design unfortunately

 

[KLF]

I would rent a cherry picker, assuming you have the room in front to maneuver it.

I learned the hard way when I had a Warn 9500 on the front of my pickup that these things need to be taken apart occasionally and relubed as maintenance. I had the same exact experience as you: motor seized, drum wouldn't unspool. The engineer at Warn informed me that it should have been taken apart before this. My motor was totally ruined, not salvageable. The gears took a lot of work to get functioning again. Lesson learned.

 

[kcjaz]

My Trail Tailor is a one piece design unfortunately

sounds like the justification to install a gantry crane in your garage!

 

[kcjaz]

I learned the hard way when I had a Warn 9500 on the front of my pickup that these things need to be taken apart occasionally and relubed as maintenance. I had the same exact experience as you: motor seized, drum wouldn't unspool. The engineer at Warn informed me that it should have been taken apart before this. My motor was totally ruined, not salvageable. The gears took a lot of work to get functioning again. Lesson learned.

This made double check maintenance for my Warn Zeon 12S. I thought it was water proof and it is (IP68). I didn't really full appreciate the benefit of that. You definitely pay for it but I'm glad I did.

Found this via Google:

Four Tips to Maintain Your Winch

Here are four steps you can follow to keep your winch running in tip-top shape.

www.warn.com

 

[linuxgod]

I learned the hard way when I had a Warn 9500 on the front of my pickup that these things need to be taken apart occasionally and relubed as maintenance. I had the same exact experience as you: motor seized, drum wouldn't unspool. The engineer at Warn informed me that it should have been taken apart before this. My motor was totally ruined, not salvageable. The gears took a lot of work to get functioning again. Lesson learned.

That sucks, because obviously getting access to mine is a PITFA.

 

[skrypj]

The arb on my Jeep Liberty I could lift off myself by hooking my arms though the loop. No winch though.

The Addicted offroad bumper on my 4Runner I used my ceiling mounted lift in my garage that I had originally installed to lift and store my F150 fiberglass topper.

 

[fjc-man]

I have a winch on a trolley track.