Off-Road Recovery Winch Maintenance

When inspecting the winch cable, look for kinked or frayed wires along the entire length of the line. If any are discovered it’s time to replace. Don’t forget to also inspect the winch hook and pin for damage or irregular wear. If anything looks suspect you’re better off replacing it than worrying that it may fail. We can’t repeat this enough — inspect winch rope/cable on a regular basis and always after use.

Solenoid failure is typically caused by water. It can be better protected by mounting it under hood or by using a winch cover. If the solenoid becomes submerged in water it should be inspected and tested for damage. Carrying a spare solenoid is a good idea for wet weather ’wheeling.

With synthetic rope damage is often easier to spot. Mild abrasion to the outer rope filaments may cause the rope to look fuzzed but this typically won’t affect performance. If you find any rope fibers that are melted or fused from excessive loads or cuts or exposed core fibers, the winch line needs to be replaced. When using synthetic rope it is a good idea to employ a protective sleeve over the rope wherever it may contact rocks or other objects that may abrade the rope.

Most winches don’t require lubrication for the life of the winch, except in the case of a complete disassembly and repair. You should check with the manufacturer for details on the maintenance of your specific winch. If it is submerged in water or mud, however, we recommend disassembly, inspection, and cleaning with penetrating oil. The gears should be lubricated with high-pressure synthetic grease. This is also a good time to replace the winch cable.

You can extend the life of your winch and line by making sure you have the correct weight capacity winch for your 4x4. A 5,000-pound winch on a near stock Jeep will cut it. Add 37-inch tires, heavy, bumpers, and big axles and it’s time to upgrade to an 8,000-pound unit or better. Since it’s best to match your equipment strength with your pulling strength, if you upgrade your winch it’s time to upgrade your rigging to match.

A winch will not only last longer but also work better when kept clean. Use a clean rag or towel to remove surface dirt and debris from the winch motor and housing, winch cable, electric cable connections, and switch control. It’s also a good idea to unwind the cable (leaving at least five wraps on the drum), wipe it clean, and re-spool it properly. You can also lightly oil the winch cable and hook to prevent rust and corrosion.

Proper winch mounting will ensure your winch stays attached to your 4x4. Use Grade 8 hardware and make sure the mounting bolts are properly torqued. Practicing safe winching techniques, such as not over-loading the winch, will help keep your winch working as needed.

Use a wire brush to remove contaminates and buildup on the winch motor power cable terminal posts. Then coat the terminals with either a Lithium-type grease or Vaseline before installing the color-coded rubber boots over them.

A protective sleeve should be used over a synthetic winch line. This sleeve served its purpose well, saving the winch line from damage as it scraped over rocks during multiple winching maneuvers. The damage to the line eyelet, however, is enough to warrant replacement.

Once a winch cable becomes stretched it needs to be replaced. A stretched cable could lead to line failure while in use, which could cause great damage or even death. Inspect your winch cable/line regularly to avoid such situations.

Proper care of your winch and winch cable will ensure that it’s ready for action when needed. We see this a lot. If you are too lazy to re-spool your winch cable after use, you’re simply asking for trouble the next time it’s needed.