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Winch Solenoid Issues

vtblazer

vtblazer

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Have a Warn CE XD9000i that 'at times' only clicks when trying to pull in.
Then other times, it works fine.

Yeah, it's a solenoid but there's 4 of em (I know they operate in pairs) but when tested individually, they ALL test to be good. :doah:

Even if I wanted to replace a pair, does anybody know which two are the 'in' solenoids for this Warn?

Did the goggle thing but didn't find any decent schematics.

They sell all four as a replacement package but it's $250.00 bucks, so I'm hoping to change out only two @ 25.00 bucks each instead.

Intermittent problems really bite!
 
I'd be suspicious not of the solenoids proper but the connections. Take EVERY connection apart, cleaning with fine sandpaper or a file.

Check the wires' ends carefully; if there's any side of corrosion, replace the wiring.

Betcha that'll fix it.

-- A
 
Thats the same thing I went though on sat.....Check the grounds on one side (Small terminals) of the solenoid. They all are connected together and only have one ground point. The two solenoids that work together are chris crossed from each other. It's hard to test them when their hooked up because they are connected together on both polls.
I looked for a diagram too...Couldn't find anything ether.
I took one of the bad ones apart and found the bar that makes the contact between the two polls was burnt and not making good contact. All the winding looked fine. It looks like heat is the killer.
 
Had my 8274 just click one of the few times I needed it, thought it was a solenoid problem, took the cover off and just one of the nuts had vibrated loose, tightened it up and it worked fine.:doah:
 
I've got schematics on those 4 solenoid systems if i can find them. They are on the computer somewhere. Don't worry, I'll find them either tonight or tomorrow.
 
Found 'em. Don't know if they are for your type winch, but most of them work the same.
Note: there are two different schematics here. Its not obvious just by looking since there is no divider.


J.

8274 schematic.jpg

s2500-s3500-s4500.jpg
 
The top one I had found, it's for the old style 847..? Something warn.
Thanks though.

All the connection's 'look' excellent and like new but I'll pull it apart the put to goop to it anyway.

DSC01660WinchGuts.jpg
 
Okay, I've devised a quick fix.

I'm going to simply switch leads coming from the 5 pin plug, so that the two solenoids that get used to pull in, will now be the two that spool out.

Gets me the two that are currently working correctly being used to tug.

It means only having to swap around 4 wires.
 
vtblazer said:
Okay, I've devised a quick fix.

I'm going to simply switch leads coming from the 5 pin plug, so that the two solenoids that get used to pull in, will now be the two that spool out.

Gets me the two that are currently working correctly being used to tug.

It means only having to swap around 4 wires.
Click to expand...



Frack...:(

No idea why but it didn't work at all that way, only the solenoids clicked...peiod.
 
FIXED!


Turns out it was #3 solenoid.
Testing individually with a meter found the one 'not' closing the circuit.

*Connect power to the cables
*Use a jumper wire to energize one side of the solenoid
*Ground the other side (smaller posts) while toning out between the two larger posts and you'll find the one not working

Pulled it out, pulled it apart, cleaned up the connection's & applied some dielectric silicone and reassembled.

Don't try using rivets to put it back together, the body is brittle and won't take the stress, use screws/nuts.

Yeah, found out trying and busted out one of the corners. :crazy:

DSC01675WinchRepair.jpg

DSC01677WinchRepair.jpg

DSC01678WinchRepair.jpg
 
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