warn winch slipping

[derrick]

i have a warn winch on my kawi an a buddy was trying to winch me out buy hooking winch to winch and he done what i told him not to do he jerked it was working fine till he got carried away now it wont pull under load cable just shakes an u can hear it slipping but when the bike is on a smoth surface it will winch me and the bike till i touch the brakes to put a little load on it any ideas nothing looks damaged inside

 

[blastoff]

i have a warn winch on my kawi an a buddy was trying to winch me out buy hooking winch to winch and he done what i told him not to do he jerked it was working fine till he got carried away now it wont pull under load cable just shakes an u can hear it slipping but when the bike is on a smoth surface it will winch me and the bike till i touch the brakes to put a little load on it any ideas nothing looks damaged inside

gears are stripped, they can be replaced

 

[fat tire]

i have a warn winch on my kawi an a buddy was trying to winch me out buy hooking winch to winch and he done what i told him not to do he jerked it was working fine till he got carried away now it wont pull under load cable just shakes an u can hear it slipping but when the bike is on a smoth surface it will winch me and the bike till i touch the brakes to put a little load on it any ideas nothing looks damaged inside

Warn has plastic gears/dogs.......you probably have the leading edge of the teeth worn or broken off but the rest of the gear is in tact.... it will work fine untill there is load applied then the teeth will slip against each other....... Pull it apart and replace the worn gear....... should be able to order a kit from warn for your winch....sometimes the kit is as much as a new winch....and sometimes the OEM parts (gears) are a little different so as the only option is to replace them in complete sets..... even if one gear looks fine you must replace both...... but keep the spares just in case...... hope this helps ya out.

 

[TheLonelyIsland]

gears are stripped, they can be replaced

was gonna say the same thing!!!!!

 

[sumx54]

Warn has plastic gears/dogs.......you probably have the leading edge of the teeth worn or broken off but the rest of the gear is in tact.... it will work fine untill there is load applied then the teeth will slip against each other....... Pull it apart and replace the worn gear....... should be able to order a kit from warn for your winch....sometimes the kit is as much as a new winch....and sometimes the OEM parts (gears) are a little different so as the only option is to replace them in complete sets..... even if one gear looks fine you must replace both...... but keep the spares just in case...... hope this helps ya out.

Its more than likely the "end cap housing Part #1" thats stripped. I have yet to see any other "plastic" gears inside of a warn winch. The gears are metal and should be just fine. I have had my rental units come back ALL the time with this problem and frankly its usally operater error. You can't Jerk on a winch cable. The rebuild parts in my opinion are VERY VERY cheap compared to a $500 replacement. And in the 15-20 winch rebuilds I've had to do , I have only ever had to replace any of the actual gears once and theres a story behind that . The end cap will run you about $43 on average and you might as well change the drum bushings for $5 (p#9)while your at it. Clean everything up very well before putting it back together. I use a heavy wheel grease to pack the gears with when I do it. I give this project rebuild a time frame of two beers (45 min.) Good Luck and here's a parts list for ya .

 

[crisscross1]

I had a similar problem, it ended up being the drive shat in the winch, cost was less than $20. The end wheres round and wont stay engage and has a ratcheting sound. They look difficult from the out side until you open it, they are very easy to work on, Good luck.

 

[caddy]

Mine is starting to do that too. Guess I should fix it before I really need it again.

 

[buck50]

sometimes the winch is just packed with mud inside! i've had to clean mine out a couple times, and it always worked much better after. unless the plastic gears are gone like others have said. easiest way to tell is to pull it apart, which you have to do to clean it anyways. then you'll know if it's just packed with mud, or stripped out

 

[AreWeThereYet]

I haven't even checked to see if mine works this year :d call me an optimist. I am hoping it's crapped out so I can buy a Viper 4500

 

[fat tire]

I haven't even checked to see if mine works this year :d call me an optimist. I am hoping it's crapped out so I can buy a Viper 4500

Money baggs!!

 

[AreWeThereYet]

Money baggs!!

They aren't that expensive only about $300can last I recall off eBay from Motoalliance

 

[goodngrubby]

They aren't that expensive only about $300can last I recall off eBay from Motoalliance

And they work good too. I bought a 4000lb Viper for my wife's Ranger last year, beat the hell out of it, and it hasn't missed a beat. They appear to be a little more waterproof than the numerous Warn's I have destroyed.

 

[sumx54]

Not a bad deal if it works.

 

[AreWeThereYet]

Not a bad deal if it works.

This is the one I am looking at

 

[teeroy]

I see a lot of guys using their winches as tie downs for transport, bad idea. it will wear the plastic housing gear teeth ("end cap housing Part #1") exactly where the three metal planetary gears contact the teeth.

also have had to repair the shaft that crisscross refers to, I just welded onto it and shaped it like a new stock shaft. seems like it got shorter somehow and wouldn't engage.

 

[Sofa king]

tow rope ftw