Winch busted or repairable?

[HeavyPizzaz]

Took the Intercooler guard off my NX to replace with a Boo’s Bash Plate last night and found this situation on the back of my Warn Tabor 10K winch...





Those two bolts on the right ain’t meant to be hovering in thin air. If I didn’t know any better I’d say the line hasn’t been spooled on correctly, or the line is too long, or a combo of both. Looks like it’s been broken a while.

Winch still works... I’ve used it a few times. Looks like these are essentially a stop guard but what should I do. Just leave it? I was thinking of replacing the line with a synthetic one anyway.


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[old Jack]

The tie rods are to keep the motor, at one end of the spool, and the gearbox, at the other end of the spool, all aligned correctly, so it is important to fix this. Since it is a Warn you should be able to buy the end plate as a spare part, most likely online will be the cheapest.


It is likely the end plate has failed because it has been over stressed too many times with the wire rope bunched up at one end of the spool.


If fitting a synthetic rope ensure the first layer of rope has a heat proof sleeve over it as the spool drums can get very hot and damage the synthetic rope.



OJ.

[Onslow]

The tie rods are to keep the motor, at one end of the spool, and the gearbox, at the other end of the spool, all aligned correctly, so it is important to fix this. Since it is a Warn you should be able to buy the end plate as a spare part, most likely online will be the cheapest.


It is likely the end plate has failed because it has been over stressed too many times with the wire rope bunched up at one end of the spool.


If fitting a synthetic rope ensure the first layer of rope has a heat proof sleeve over it as the spool drums can get very hot and damage the synthetic rope.



OJ.

X2.

There is a winch expert in Melbourne who manufactures extended Tie-Ends to minimise this issue, for those times when you absolutely have to winch on an angle, which as OJ mentioned, causes the cable to bunch up at the ends of the drum.

[HeavyPizzaz]

The tie rods are to keep the motor, at one end of the spool, and the gearbox, at the other end of the spool, all aligned correctly, so it is important to fix this. Since it is a Warn you should be able to buy the end plate as a spare part, most likely online will be the cheapest.

It is likely the end plate has failed because it has been over stressed too many times with the wire rope bunched up at one end of the spool.

If fitting a synthetic rope ensure the first layer of rope has a heat proof sleeve over it as the spool drums can get very hot and damage the synthetic rope.

OJ.

Thanks very much OJ. Excellent info. I found an exploded diagram of the winch, including all part numbers and I can go from here. Looks like I'll need to be taking the bull bar off sometime this year then! Do you think it's a big risk if i needed to use the winch in the meantime? I suppose it's hard to know.

[HeavyPizzaz]

X2.

There is a winch expert in Melbourne who manufactures extended Tie-Ends to minimise this issue, for those times when you absolutely have to winch on an angle, which as OJ mentioned, causes the cable to bunch up at the ends of the drum.

Thanks mate, any chance you have any leads for me? I did a google search for them but couldn't find anything.

[Onslow]

Thanks mate, any chance you have any leads for me? I did a google search for them but couldn't find anything.

Malcolm Leslie at S.G Leslie and Sons in West Heidelberg.

Address: 19 Mologa Rd, Heidelberg West VIC 3081
Phone: (03) 9459 2859

Can't recommend this guy enough - old school but really knows his stuff.

[old Jack]

Thanks very much OJ. Excellent info. I found an exploded diagram of the winch, including all part numbers and I can go from here. Looks like I'll need to be taking the bull bar off sometime this year then! Do you think it's a big risk if i needed to use the winch in the meantime? I suppose it's hard to know.

Yes, in a high load winching operation there could be enough load to induced flex that could damage the winch, particularly if the winch is mounted so the mounting base of the winch is vertical as this that puts compression or tension loads on the winch base attachments, and the tie rods are designed to counteract these forces. If the winch is mounted with the base in the horizontal plane then one tie rod is in compression and on is in tension whilst the base mounting bolts are in shear so the loads on the tie rods are reduced.


As a temporary repair you could see if you could relocate the tie rods back into the correct position and tighten the cap head screws firmly, there maybe enough metal left on the end plate to take moderate winching loads in an emergency. This will only work if you re-spool the wire rope evenly and keep it that way.


OJ.

[Pwoffey]

If fitting a synthetic rope ensure the first layer of rope has a heat proof sleeve over it as the spool drums can get very hot and damage the synthetic rope.

OJ.

OJ, is this the case for any winch, or just those with the brake in the drum? The makers of my Sherpa winch claim that because its brake is in the gear box, and not in the drum, heat damage to the rope on the drum should not be a problem. Is that claim reasonable?

[old Jack]

OJ, is this the case for any winch, or just those with the brake in the drum? The makers of my Sherpa winch claim that because its brake is in the gear box, and not in the drum, heat damage to the rope on the drum should not be a problem. Is that claim reasonable?

Yes it is a reasonable claim. I should have clarified it was for an in spool/drum brake winch.

OJ.

[hounddog]

Winch Woes

My 5 year old recovery winch ( bought on ebay) has a broken brake spring, I have searched high and low to try and source the part as it has no manufacturers mark with no avail. it has a 2way spring inside a hub on the drum axle wich I found unusual (see pics) any advice for a solution is appreciated as for the cost to get this part should outweigh trashing the entire unit that has a perfectly good motor and gearbox