tech question: Warn 9.5xp not spooling, just clicking in the solenoid

M

McFly2003

New member
So I replaced my winch line today and when I went to re-spool the new line onto the drum, I made it maybe 2/3's-3/4's the way in, taking breaks to let it cool down every 20 seconds or so, and it just stopped. After letting it take a break for a couple of minutes, I went to spool the rest of the line in and all I got was a loud click from the solenoid pack. I then went to spool it out to see if that would work and I got the same thing. The pull was extremely mild, just up and very gradual uphill, so I' almost certain I wasn't overworking the motor. I also felt it with a bare hand after it stopped working and while it was slightly warm, it definitely wasn't hot.
I have heard of people tapping the solenoids with mallets or screwdriver handles but none of this worked. I also took the cover off of the solenoid pack and it was quite clean.
I am no electric's expert and I did not buy this winch new. It came on the truck, however, I know for a fact that with the exception of when Slee spooled the original cable onto the drum, I am the first person to actually run the winch.
Does anyone here have any insight? I will call Warn tomorrow but thought I'd see if there was any wisdom on here. The Winch was professionally installed by Slee Offroad and again, has never been run other than spooling the cable. Now I have 20' of brand new synthetic line wrapped around the bars on my ARB...no bueno
 
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McFly2003 said:
So I replaced my winch line today and when I went to re-spool the new line onto the drum, I made it maybe 2/3's-3/4's the way in, taking breaks to let it cool down every 20 seconds or so, and it just stopped. After letting it take a break for a couple of minutes, I went to spool the rest of the line in and all I got was a loud click from the solenoid pack. I then went to spool it out to see if that would work and I got the same thing. The pull was extremely mild, just up and very gradual uphill, so I' almost certain I wasn't overworking the motor. I also felt it with a bare hand after it stopped working and while it was slightly warm, it definitely wasn't hot.
I have heard of people tapping the solenoids with mallets or screwdriver handles but none of this worked. I also took the cover off of the solenoid pack and it was quite clean.
I am no electric's expert and I did not buy this winch new. It came on the truck, however, I know for a fact that with the exception of when Slee spooled the original cable onto the drum, I am the first person to actually run the winch.
Does anyone here have any insight? I will call Warn tomorrow but thought I'd see if there was any wisdom on here. The Winch was professionally installed by Slee Offroad and again, has never been run other than spooling the cable. Now I have 20' of brand new synthetic line wrapped around the bars on my ARB...no bueno
Click to expand...


Sounds like it COULD be a loose wire. Check all your connections to your battery and all the connections in your solenoid box.
 
All connections seem to be O.K. I'll have to sit down and watch that vid, though the solenoid that that guy is working on looks absolutely nothing like what I've got going on. If it helps anyone knowledgable, it cut out to the "clicking" one other time on the pull, earlier on, and once I stopped and started it up again, it went on like nothing had happened.
 
Sounds to me like either a bad solenoid or maybe the solenoid not getting enough power(IE short in the power/ground wire or loose connection)
 
Try This

I had the same problem with my Warn 9.5xp, hawling logs for a couple of hours then no winding just clicking solenoid, had to remove cable as it broke fully extended. I checked and cleaned every connection, researched for a month and only solution found on boards was take out winch motor and replace or recondition. It is realy hard to remove my winch with my Shrockworks bumper, so I tried the "starter motor fix" I put a wood block on winch motor and whacked with mallet a few times. The winch then started winding in both directions, pulled truck full length of cable twice, two months later it still works!
 
i know this doesnt help you...
but, typical warn crap.

they used to make GOOD stuff...but not anymore.
 
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