Well some of you know I have been having issues with my winch.
Short story is - since I've owned it, the 'retract' side has always had issues.
Tapping on the contactor ALWAYS fixed it.
Then it got harder and harder to get it to go.
Eventually got to the point that once it 'caught' I had to stay on it, or letting off it wouldn't work again.
Everyone said it's the contacts, it's the winch, it's junk, toss it, switch wires, etc.
But that didn't fit my scenario. I know enough about this type of stuff to know that it was not dirty contacts or a dying winch.
Well tonight I got it off the machine to dissect it.
Here's what we got. Remember a lot of other brands will be similar, some not. All I needed for this job was my leatherman.
First thing I did was cut the zip tie off around the switch wires, knowing I wouldn't have enough play inside the box.
Then I started removing the screws holding the two halves together. As I did this, I noticed a lot of spring power pushing the halves apart, so I tensed up my grip on the two pieces to avoid things flying out.
This is what I wound up with.
First thing I dug into was the terminal side, two screws and the cover is off.
One thing to note, every screw on this thing is the same size! BONUS!
I noticed one of the slides wasn't very smooth, the contact plate in the center of the piece was twisted. I removed it via the corresponding nut on the terminal and slid it out, made sure that right side moved smooth, reinstalled the terminal and checked again with the plate nice and straight. Perfect motion now. I sense this 'sticking' may have caused the damage on the other side, which you will soon see.
The terminal goes back in, o ring over the stud, then flat washer, lock washer, and nut.
Now, to start on the other side.
Remove the two slides and springs from the center.
Remove the two screws at each corner of the plate, and the one screw in the electronic board. Gently pry the board up while feeding in the wire from the back to not tear it.
The whole block should slide out, carefully.
Take a peek.
Yes... there's the problem. The super thin wire that makes up the coils which create the magnetic energy to 'relay' the power... have disconnected from the board. Up until a week ago, I could always let cable out, just not in. Then that stopped too.
Take a close look and you can see how thin the wire is, and where they are supposed to be attached. Not sure if it was excess heat, or the 'sticking' slide part of the relay in the other half that burnt the wire right out of it's solder.
So now I have to see if I know anyone with sharp enough skills to solder some new leads to the board, attach them to the coils, and heatshrink them all. Because the entire assembly is in rather perfect condition otherwise. The overall quality is impeccable, but the weak point is clearly in the coil wiring.
Obviously, to put it all together just reverse all said steps. Just make sure the springs and slides align right etc. I did choose to put mine together for now until I can find someone to fix it. Anyone have suggestions on what type of business might fix such a thing? It's gotta be a cheap fix, it's only a 4 solder points and some heatshrink. Just very delicate.