PART ONE: The WinchWe've been having some fun lately with all sorts of winches. But to date we've never done an OEM Toyota electric winch rebuild. @Sonofaskipper 's truck finally gave us the opportunity to totally nerd out on the winch. This is the winch that typically came with JDM 81 Series Land Cruisers found on trucks in Japan. The ones we see now are typically past the Federal 25 year rule or were previously Canadian vehicles. With the age of these right hand driver diesels we expect to see more come stateside.
There were two types of winches that Toyota produced for the Land Cruiser, either the PTO which which is all mechanical or the electric winch driven off an electric gear reduction motor. On this JDM 81 Series its the electric variant. This truck arrived to us with the winch never working for the customer. Quick initial test did not bode well.
The first thing to take a look at was what was under the plastic cover. Once off you get access to the LOCK/FREE spool handle, which is missing, and the 6-pin connector for the Toyota Winch Controller. For reference, 3600Kg is 7936lb so we can call it an 8000lb winch for simplicity. Should be plenty of power for the majority of extractions.
One of the things that was noticed was that the steel cable had some looping up top which looks like it wasn't spooled in properly after its last use. This is a piece of evidence that would lead us to its ultimate failure.
First step is getting the winch off the truck. This is pretty straight forward. A couple of bolts and the front bumper comes off in one piece. From there the Winch Support Front Crossmember needed to come off. Also no biggie, just a few bolts. Once its off you can get a clear view of the entire winch assembly. A couple of bolts removed from the bottom, plus a few battery cables removed from the solenoids, and the winch comes out. Its a pretty heavy beast. Once its reassembled it'll get weighed with the new winch rope.