Warn 12000 rebuild question.. that turns into answers -testing-

[Mikesta]

Figured I'd pose this question here as someone may know where to find this info.

I'm trying to rebuild a Warn 12000lb winch.

Issue: Will make a noise when releasing cable. A clicking noise.
Issue: Will not make a noise when retrieving cable.

The pictures of this winch are below and there is a Stamping of 03/85. Is this from 85? Wow.

I have prowled through Google looking for parts and perhaps guides on how to rebuild one of these. Does anyone have any ideas? done this before? or know of a good site for this info?

Thanks!

 

[Mikesta]

http://www.members.shaw.ca/macks4runner/winch.htm

http://4wheeldrive.about.com/gi/dyn...www.jonfund.com/technical/winchteardown.shtml

 

[freightdog]

http://www.shercosales.com/

I rebuilt mine on the 60 many moons ago...and these guys were a world of help complete with Schematics

 

[Mikesta]

Thanks for sharing that frieghtdog... I think this is mine right here.

Great schematics

http://www.shercosales.com/index.asp?PageAction=VIEWPRODGROUP&ID=78

 

[Mikesta]

I spoke with Jason and he faxed me over these directions for eliminating the motor as the problem. Thanks Jason!

-Winch Motor Test procedure-

1. Put winch in free-spool.

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" to 6" dead lead, 8 gauge 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 on 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.

if these steps are followed correctly and the motor runs in both directions... the motor is good.

 

[Mikesta]

Those are some easy instructions.

My winch motor is perfect. But need a new Warn power pack. $250 plus the ride.

I'm going to try to clean up the contacts on the wiring tonight and see if its just a bad ground.

 

[Liam]

Those are some easy instructions.

My winch motor is perfect. But need a new Warn power pack. $250 plus the ride.

I'm going to try to clean up the contacts on the wiring tonight and see if its just a bad ground.

did you find out what the popping noise was??? I have the same winch, a bit newer but still the same......when i am spooling out i hear some sounds like that as well......was told that is what is should sound like........

 

[Landpimp]

pretty sure my 12 and 10k's both sound like that......even when new

but hell I aint pulled cable in years

did you find out what the popping noise was??? I have the same winch, a bit newer but still the same......when i am spooling out i hear some sounds like that as well......was told that is what is should sound like........

 

[Mikesta]

did you find out what the popping noise was??? I have the same winch, a bit newer but still the same......when i am spooling out i hear some sounds like that as well......was told that is what is should sound like........

Not yet Noah. What I hear though is that its due to a bad ground. The person from Warn was very helpful and knew his stuff. I've ordered a new control pack anyway... the OEM one for this model which isn't available anymore. The pack they ship now has updated wiring. Instead of 3 wires and the ability to use a paper clip to pull or release the winch, they have 5 wires. The 5 wire pack will kill the winch immediatly if the chord is yanked out... some kind of safety kill switch.

Landpimp. I hope you don't pull cable anytime soon. However I do hope you are still laying the cable down.

 

[Mikesta]

Out with the old:

 

[Mikesta]

And in with the new tomorrow.

 

[Mikesta]

Question on where cable's go

I think the cables from the solinoid pack were on wrong so the original solinoids may still be good.

Does anyone have a diagram of a 3 wire solinoid pack config?

I found this link

http://www.warn.com/truck/ReplacementParts/parts/23/srrpl17-18.pdf

But cannot read it.

Looking for placement of wires from Motor to Pack and placment of wires from controller plug to pack.

Thanks

 

[dfmorse]

Mikesta;

Hopefully, some of these links to my WARN stuff will help.


http://homepage.mac.com/dfmorse/BattProj2/page12.html



In the following link, disregard the FORD stuff. I rebuilt a system for a buddy of mine with a really old WARN 6-8k winch.

http://homepage.mac.com/dfmorse/WARNwinch/index.html

...

 

[Mikesta]

Thanks for sharing that. I hope my motor isn't burned out

Mikesta;

Hopefully, some of these links to my WARN stuff will help.


http://homepage.mac.com/dfmorse/BattProj2/page12.html



In the following link, disregard the FORD stuff. I rebuilt a system for a buddy of mine with a really old WARN 6-8k winch.

http://homepage.mac.com/dfmorse/WARNwinch/index.html

...

 

[Mikesta]

Dfmorse,

I've printed out, studied the schematics and I'm still not getting it.
Here are some pictures of the current config.

My question is where do the two wires from the motor go to?

I currently have them wired up to the old configuration that never worked because I thought the solenoid pack was bad.

Cheers

 

[Mikesta]

Saweet. After 3 calls to Warn regarding different settings and operation instruction, the winch LIVES!

There were two wires that I was struggling with because they weren't on any diagams I found. The guy from warn verified that my winch is one of the first 12000's made. From 80-82 and the 2 cables coming out of the motor were thermal sensors that shut the winch down. The technician said to snip em and forget em.

I left them there. It took an hour, but I got the winch cleaned up.

Thanks for all the help Mudder's!

Pics, before/after and the 80-82 thermal wires.

 

[Mikesta]

Its in the truck

Here are some pictures of it in the truck.

Works good... pulled the LV up. Now I can get stuff around easier.