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 Post subject: Relocate Winch Controller
PostPosted: Tue Apr 12, 2011 5:58 pm 
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Location: LOST in Illinois
Took me a couple of weeks to finally complete this project

I have a T-Max winch and discovered that I could no longer winch out anymore. I narrowed it down to a bad solenoid. If you've opened up your winch control box most of them have either two or four high voltage solenoids one(set) for winch out and one(set) for winch in. I believe Warn uses 4 for redundancy/reliability, and to split the current between two relays, but most other winch mfgs use 2 higher amp units.

The T-MAX has two solenoids. I tested the relays by applying 12 volts to the relay inputs (the two terminals above the yellow stickers with the small gauge wires attached.
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I decided that while I was at it, might as well relocate the controller under the hood and clear that big obstruction from the grill.
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So First step was to get a new solenoid. Found exactly what I needed on ebay for $23, but a little more research I found a dual solenoid in a nice little package for $65 with free shipping. This unit looked like it would be easier to find a spot for it under the hood than the trying to find a spot for the stock unit.
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2005 CRD "Ol' Blue"
Red Ryder carbine-action, two hundred shot range model air rifle with a compass in the stock and this thing which tells time.
My build page- RL Komodo Rear and TJM Front Bumper, armored, lifted, JBA Steel D30, 4.10s and ARB air lockers.


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 Post subject: Re: Relocate Winch Controller
PostPosted: Tue Apr 12, 2011 5:58 pm 
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Stock cables were designed for mounting the unit on top of the winch so they were way too short. I priced out some 2 guage wire at Home Depot and was shocked at the price. Went down to Tractor supply and found some very nice 2 gauge welding cable at a fair price, and bought 18ft. I reused the ground cable which was long enough. Could have reused the power lead to solenoid, but had enough welding cable to replace it, so I did. You should measure, but I think 14 feet would be more than enough to replace the three motorleads. Also bought #2 lugs from Tractor Supply and some rubber connection boots off of ebay.

Ok, now to find a spot for it. Right behind the driverside headlight. There is a nice bracket there that I can modify to mount the solenoid.
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So I cut out a piece of steel and welded to the bracket, Drilled and tapped a couple of holes for the solenoid and painted it.
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Ran the cables from the solenoid to the winch, Solenoid to the battery and wired up the hand control socket.
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_________________
2005 CRD "Ol' Blue"
Red Ryder carbine-action, two hundred shot range model air rifle with a compass in the stock and this thing which tells time.
My build page- RL Komodo Rear and TJM Front Bumper, armored, lifted, JBA Steel D30, 4.10s and ARB air lockers.


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 Post subject: Re: Relocate Winch Controller
PostPosted: Tue Apr 12, 2011 6:00 pm 
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All cleaned up.
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Schematic
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2005 CRD "Ol' Blue"
Red Ryder carbine-action, two hundred shot range model air rifle with a compass in the stock and this thing which tells time.
My build page- RL Komodo Rear and TJM Front Bumper, armored, lifted, JBA Steel D30, 4.10s and ARB air lockers.


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 Post subject: Re: Relocate Winch Controller
PostPosted: Tue Apr 12, 2011 11:53 pm 
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Location: ky
That is a very clean set up. 8)

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 Post subject: Re: Relocate Winch Controller
PostPosted: Sun Apr 17, 2011 11:00 pm 
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Did not see the bracket I used installed in any of the gas Liberty's I looked at this weekend during the Illinois wrenchfest. Every one of the Jeeps (02-05) had the mounting point on the fender for the bracket, but none had the bracket.

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2005 CRD "Ol' Blue"
Red Ryder carbine-action, two hundred shot range model air rifle with a compass in the stock and this thing which tells time.
My build page- RL Komodo Rear and TJM Front Bumper, armored, lifted, JBA Steel D30, 4.10s and ARB air lockers.


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 Post subject: Re: Relocate Winch Controller
PostPosted: Fri Apr 22, 2011 4:43 pm 
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Added winch controls to the center console. Toggle switch UP=in, DWN=out, LED Arm switch
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_________________
2005 CRD "Ol' Blue"
Red Ryder carbine-action, two hundred shot range model air rifle with a compass in the stock and this thing which tells time.
My build page- RL Komodo Rear and TJM Front Bumper, armored, lifted, JBA Steel D30, 4.10s and ARB air lockers.


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 Post subject: Re: Relocate Winch Controller
PostPosted: Mon May 02, 2011 11:56 pm 
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Good job. Someday I'd like to wire remote switches for my winch into inside my KK.

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2009 KK Limited 4x4
Jeep Green/partially dechromed/Sunroof/OEM Skids/
Gray Leather/uConnect GPS-Nav/DVD Head Rests/
MtnLuvr's Off-Road Front Winch Bumper, Heavy Duty Rock Sliders, Heavy Duty Off-Road Rear Bumper/JBA 4" AaS Lift w/UCAs/16x8's w/ 245/75R16 GY MT/Rs

Coming: :twisted: :JEEPIN:


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