Warn Winch Woes
 

OK started to troubleshoot my winch problems and after taking a look at the solenoids, I realized I had found my problem... :eek2:

The corrosion on the far right use to be a bolt :nono:

http://www.flightwear.net/Randy/solenoid1.jpg

http://www.flightwear.net/Randy/solenoid2.jpg

Notice how the terminals on the upper solenoids are in fine shape

I have only had this winch for about 1-year. I guess this is a testament as to what water and electricity can do to metal.

I have the contral box mounted on the winch under the bumber like this:

http://www.flightwear.net/Randy/4Runner 001sm.jpg

I guess I should have drilled weap holes on the outer cover so the water can drain. Hindsight is always 20/20.

Where can I buy replacement solenoids?

Or given the condition of everything am I better off buying a whole new box from Warn?

re
 

Randy, just go get a new bumper and winch, then give me your old one, j/k im looking at getting this stuff, not sure what its called, but its like paintable electric tape, im thinking about trying that, maybe you could clean them up "real" good, see if that helps.
Ric

Follow-up
 

I just got off the phone with Warn.

To buy an all new controller box will run $190 (Part #: 38842)

To buy new solenoids will run $14/ea. (Part #: 28396)

I'm opting to buy the solenoids and replace the existing ones.

I'd like to add I was very impressed with the Warn customer support.

hopfefully new solenoids will cure your problems.

when i mounted my control box, i took off the cover and drilled about 12 holes in the box and so far no problems with water damage. note: mine is mounted in the same location.



http://www.4x4runnin.com/images/solenoid1.JPG

http://www.4x4runnin.com/images/solenoid2.JPG

Ryan-

I'm definitely drilling holes.

I spent about an hour yesterday searching in the engine compartment and elsewhere for a possible location other than under the bumper. Basically, us 6-cylinder guys are screwed.

I guess we could bring it into the cab, but imagine the size of hole you would need to put in the firewall to get all the heavy gauge cable through.

How is the zip tie holding up? I used adjustable hose clamps, which requires me to remove the bumper to get the control box off...PITA!

I'll definitley try the zip tie approach in the mean time.

zip ties have been great Randy. i connected about 4 of the smaller zip ties to make one long zip tie. then i fed it around the winch and the box, connected the end of the zip tie and tightened it.

if i want to take off the control box, ill just cut the zip tie(s).

zip ties are great, im sure i have about 50 scattered throughout the vehicle.

another thing to consider about moving the solenoid inside the engine is that the wires will not reach, you will need to get longer ones.