Winch is dead

[WV Mtneer]

So the winch on my '11 died last week at the worst possible time. Wouldn't power in or out and no solenoids clicking. Just dead. After much work I was able to get unstuck and avoid walking 7 miles out of the mountains. I contacted warn and they were extremely helpful, but they told me that I couldn't buy parts through them. I'd have to go through the dealer. They did send me the service manual with all the test procedures though. So I dropped the winch out of the truck last night. The motor tested out fine, but 2 of the relays showed bad. I'm absolutely not an electrician, so before I go order the relays can you guys think of anything else I need to check? I feel like a poser riding around with an empty fairlead under my bumper.

[Retired BLM Rig]

Did it quit in the middle of winching, or was it dead from the moment you tried to use it last week?

[WV Mtneer]

It quit about 10 seconds into the pull. Nowhere near enough to overheat, but luckily just enough to get me pointed in a better direction.

[cruz]

Thermal Protection ? MAYBE, but I doubt it, but wile you have your winch out this is an easy mod.

http://www.dodgetalk.com/forums/showthr ... ht=thermal

[Retired BLM Rig]

This is what my owners manual says (2008).
How old is your battery? It may have tripped the low voltage interrupt. Do you have one or two batteries?

Low Voltage Interrupt
Your winch is equipped with a device that will interrupt winch function if the vehicle charging system voltage drops to a low level. The winch will not power-in or out for 30 seconds if this device is tripped. If the interrupt is tripped, the vehicle should be operated at high idle for a few minutes to allow the vehicle charging system to recover before continuing to winch.

Winch Motor Thermal Protection
Your winch is equipped with a thermal protection device in the motor. If the winch is operated for an excessive duration, the device may interrupt motor function to protect the winch motor. During this time the winch will power-out but will not power-in. Allow the winch motor to cool for a few minutes before continuing to winch. The winch will resume normal function once the motor cools.

[WV Mtneer]

I think I will try the thermal protection mod, but I've worked the winch much harder than this in the past, and never had a problem. As far as the battery, I only have one. I bought the truck used less than 2 years ago and I've never replaced it, but I have no idea how old it is. Obviously I tried the winch several times after it crapped out and it never did anything. So I'm pretty sure it's not the thermal override. I guess it could be the low voltage protection but i haven't had any any other indications of a weak battery.

[Retired BLM Rig]

Check all your connections between the battery and winch, they need to be perfect. Any corrosion could create a voltage drop causing the low voltage interrupt. If the winch can't see an accurate system voltage, it may think it's discharged and inhibit the relays from working.

[WV Mtneer]

Update:

Thermal bypass, LVI bypass, 4 new solenoids, several cold beverages, and still a dead winch. Finally figured out that the problem was the connector where the remote plugs in. The back of the 5 pin plug was corroded and one of the wires had completely fallen out. Man I feel like an idiot. Anyway, I stuffed it with some speaker wire and at least got the cable spooled back in. I guess I'll go to the dealer tomorrow and see if they can get me a new connector. By the way, when I went last week to check on the solenoids, they had never heard of a dodge with a factory- installed winch. SMH.

Also, they wanted $78 for a single solenoid. I found a 4-pack online at DB Electrical for $59 from the part number for a M15000. They work perfectly so far.

[cruz]

I guess I'll go to the dealer tomorrow and see if they can get me a new connector...

Let's compare $$$ to what the dealer will want...

https://www.amazon.com/Warn-39886-WARN- ... socket+kit

... and while your buttoning everything up, coat all the connectors with dielectric grease.

[Redman1973]

I would also add the following...

The male connectors (pins) on the winch remote have a bad habit of getting lose and pushing up inside the rubber mold.

Get some super glue and add a small drop on the pins where they meat up with the rubber mold, this will prevent a lose connection.



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