WARN 9.5ti
WARN

New Winch - Click to Enlarge

   

11/28/04 | Update: 11/12/05 | Update 6/30/07

4X4 ICON 2000 - 2008 The DVD! - Click here for details!

4X4 ICON 2000 - 2008 The DVD!

 

Specifications | How to Calculate Winch Loads | Winch Load Calculator (Excel Spread Sheet)

Winch Plate | Install | Front Number Plate Holder | Remote Throttle | Winch Kit | Winch Instructions | Battery | Cover

Understanding the DC electric-powered WINCH

 

Background

I had a car crash that did extensive damage to the front of my Jeep.  Ironically enough, the winch survived without a mark even though the winch plate was damaged badly enough to require replacement.

When I went to pick up the Jeep after the repair, I discovered the winch mounted on the vehicle backwards.  That was dumb but no big deal.  However, when I looked at the winch I discovered that the front of the winch had been deeply gouged!  Referring back to photos taken after the accident but before leaving the Jeep at the body shop, I was able to show that the damage occured at the shop.   To their credit, the shop agreed to replace the winch.

9.5ti

New Winch - Click to Enlarge

I referred them to the Quadratec web site for a price that included shipping and tax.  They cut me a check for that amount and I contacted Quadratec to replace the winch.  I decided that since I had an opportunity to reevaluate my choice of winches without losing any money, I should check to see what I might like instead of the x8000i.

Even though the x8000i had served me well without failure, I was forced to admit that there were times when I would have liked to have a faster line speed, greater capacity, and more cable.  Also, a couple times, the bail lever had gotten a little stuck in wet cold weather and I though better waterproofing might be useful.

So for a few more dollars out of my own pocket, I ordered the 9.5ti.  I was able to invoke the Quadratect price-matching and get it down a few bucks, and soon it was sitting on my door waiting to be installed.

ImagePhotographerName:
Paul M. Provencher

Update: 11/12/05

Typical Warn Winch showing cut-away view of end cap with clutch lever and planetary gears

Upon checking the clutch lever (releases the drum from the winch motor to allow free spooling out the cable) I discovered it would not flip all the way from the free spooling position to the engaged position.  I decided to bite the bullet and open up the cover to see what I could see,  I was not happy to find that the lever disappeared into what looked like a ring gear that engaged a planetary gear.  Even more concerning was the gush of clean water that poured out when I got the end loose from the main body of the winch.  I thought this thing was weather proofed!  Well I guess it was since it kept all the weather from getting out!

I sprayed some penetrating oil on the ring gear and let it sit for a while to seep into the body some.  After about five minutes I was able to get the ring gear to rotate.  I removed the single Allen screw that held the bail lever in place and shot some more penetrating oil into the hole.  After another pause, the ring gear moved even more freely.  After working it back and forth for several minutes to loosen up the corrosion, I drained out all the crap and removed the ring gear from the end cap.

I took the end cap and rinsed it thoroughly of all debris and then wiped it clean and dry.  I sprayed it again with the penetrating oil and knocked off the loose scale that had built up on the journal surface.  Once again I wiped it clean and dry.  Then I applied some extreme pressure grease all over the journal, both the teeth and the bearing surface of the ring gear, as well as the channel where the bail lever rides.  I put the same grease on the planetary gears and the pilot bearing and motor shaft.

Then I put anti-seize grease on the several Allen bolts that hold the end cap on, replaced the rubber seal (so called...) trim ring, and bail lever to the end cap.  Finally I bolted it back in place after first making sure that it worked freely and without any resistance.  This may become a more regular activity as there are no grease fittings and it is readily apparent that water gets inside the winch...

Sorry no photos, but I was covered in grease and under pressure to get it put back together so we could run some errands.

 

 

Update: 6/30/07

Jeep after front-end painting and winch repair

The winch failed and I sent it in for service.  Full details here:  Winch Repair

When it came back I put a cover on it to keep it dry...

Neoprene Cover

 

Winch Plate | Install | Front Number Plate Holder | Remote Throttle | Winch Kit | Winch Instructions | Battery | Cover

Understanding the DC electric-powered WINCH

4X4 ICON 2000 - 2008 The DVD! - Click here for details!

4X4 ICON 2000 - 2008 The DVD!

   

Winch Plate

I used the same winch plate as previously.  The only thing was that it was replaced because of damage received in the crash.   The new plate was identical except for two things.  First, it had two sets of holes for the sway bar bolts instead of the one on the first plate.  Also, the reinforcing angle bar across the back bottom edge was was two pieces with a gap across the middle instead of the one piece that ran the entire length on the old plate.

Tomken Products

Tomken Winch Plate with Mini Brush Guard

Tomken TMW-0924-V

On 6/30/07 I refinished the plate as the powder coating had failed.

Skid Plate

Winch Plate | Install | Front Number Plate Holder | Remote Throttle | Winch Kit | Winch Instructions | Battery

Understanding the DC electric-powered WINCH

4X4 ICON 2000 - 2008 The DVD! - Click here for details!

4X4 ICON 2000 - 2008 The DVD!

 

 

Installation
Nose Installation is mindlessly easy.  I simply 
  • removed the four tow hook bolts, and 
  • bolted the winch to the winch plate, 
  • then bolted the winch plate to the frame in place of the plastic part that covers the sway bar.
  • An additional bolt goes through the radiator support.
  • The two battery cables from the winch attach directly to the battery.

If you need details, stay away from screw drivers - they can be dangerous...

Winch Plate | Install | Front Number Plate Holder | Remote Throttle | Winch Kit | Winch Instructions | Battery

Understanding the DC electric-powered WINCH

4X4 ICON 2000 - 2008 The DVD! - Click here for details!

4X4 ICON 2000 - 2008 The DVD!

 

 

Front Number Plate Holder with Winch (shown on old winch install)

Number Plate Holder

Details, details...   I knew that once the winch was in place, I was going to have to resolve a location for the number plate.  Our fair state requires a front number plate.  Running without one is looking for trouble, no matter what the excuse.  I had heard people use Mag Lite flash light clips to snap the plate onto the roller fairlead so that's what I did.  The clips are pretty beefy plastic so it looked like a good solution.

Detail of Mag Lite clip attached to spare license plate
fabricated License Plate holder with Mag Lite clips and spare plate The only problem is that when I assembled it, I tightened the nuts and bolts too much and cracked the plastic, ruining the clips.  I bought another set of clips and used some washers to spread the pressure out some, and used lock washers and thread locker to allow me to just barely tighten the bolts to the clips and to a spare number plate that I used as a backing plate.   I will also have to remember to remove the license plate from the roller fairlead by releasing the ears of the clip rather than just grabbing the plate and yanking it off...

I reattached the license plate frame, cover and license plate to the "backing plate" and clips using four stainless nut/bolts.  It came out looking very clean.  I may add a short length of chain or cable to tether the plate to prevent loss or theft.

With License Plate attachedLicense Plate holder snapped to roller fairleadNumber Plate Holder

License Plate holder snapped to roller fairlead

Winch Plate | Install | Front Number Plate Holder | Remote Throttle | Winch Kit | Winch Instructions | Battery

Understanding the DC electric-powered WINCH

4X4 ICON 2000 - 2008 The DVD! - Click here for details!

4X4 ICON 2000 - 2008 The DVD!

 

Remote Throttle

I later installed a remote throttle that enables me to run the engine at higher speeds to provide additional power and charging from the alternator during and after winching operations.

Throttle Knob on dash 

 

Winch Plate | Install | Front Number Plate Holder | Remote Throttle | Winch Kit | Winch Instructions | Battery

Understanding the DC electric-powered WINCH

4X4 ICON 2000 - 2008 The DVD! - Click here for details!

4X4 ICON 2000 - 2008 The DVD!

 

Winch Kit
A winch isn't much good without a box of things to complete the picture.  Let's face it, a spool of cable and a hook is a good start but in order to safely and conveniently connect it to an anchor point, there are a few things that are needed.  As it turns out, I purchased a number of the necessary items as a package when I bought the Hi-Lift jack.  There are only a few remaining items that I need beyond that (marked in the list below with an asterisk)
  • 1 Custom Nose Attachment  (for Jack)
  • 1 5/8" D-Ring
  • 1 8ft. Tree Saver Strap
  • 1 Pair Hi-Lift Gloves
  • 1 Carrying Case
  • 2 3/4" D-Rings*
  • 2 16,000lb snatch blocks*
  • 1 20' 3/8" chain with hooks*

 

Off-road Kit
The 20-foot chain is for providing an anchoring point to boulders.  The snatch blocks are for pulls when high strength or shortened/angled cable setups are needed.  The D-Rings are used as an anchor point for the winch hook, attached to either the tree saver or the chain.  In addition, I carry two medium-sized quilted moving blankets for multiple uses, and to dampen cable whip if it should snap during a pull.  The gloves are required for handling the cable to prevent injury from loose cable strands.  The custom nose attachment is primarily intended for use with the Hi-Lift jack when used as a winch so it may not come into play for power winching.   The case consolidates all the items needed for winching or jacking operations.

    

Winch Plate | Install | Front Number Plate Holder | Remote Throttle | Winch Kit | Winch Instructions | Battery

Understanding the DC electric-powered WINCH

4X4 ICON 2000 - 2008 The DVD! - Click here for details!

4X4 ICON 2000 - 2008 The DVD!

 

Instructions
Although not an accessory in the strictest sense, I found that, not being born with built-in knowledge of safe and effective winch operation, I would need some instruction.  I found a video from 4-Wheeling America and Bill Burke called Unstuck! that covers recovery methods and safety using a winch, Hi-Lift Jack, and nylon strap.  Since my kids love to watch videos and love to go 4-Wheeling, we sat and watched the tape over and over again.  I wanted to commit the advice to memory.  They liked watching the recovery operations - something that they will probably be far away from in real life.  And the scenery of the video is tantalizing - shot in the Colorado mountains.  It's worth the few dollars it costs and is available on Bill Burke's site.  And before I hit the trail with my new counter weight mounted up front, I spent some time practicing in the back yard.

Unstuck!

Winch Plate | Install | Front Number Plate Holder | Remote Throttle | Winch Kit | Winch Instructions | Battery

Understanding the DC electric-powered WINCH

4X4ICON.COM 2000-2003  The CD! - Click here for details!

4X4 ICON 2000 - 2003 The CD!

 

Battery

 

It finally came to pass at the end of November 2002, while traveling, that the factory battery dramatically failed and exploded.  I was fortunate to find a place where I could purchase an Optima Red Top, as planned.  I do not recommend replacing your battery under duress like I did, but if you find yourself in such a predicament, I wish you the same good fortune that I had that day...

Optima Red Top

 

Update 7/7/07

While wheeling at Oakridge I had to replace this battery.  I had drained it dead at least four times while I owned it, winched with it several times  It owed me nothing.  Definitely bought another new one to replace the one I had!

 

 

Winch Plate | Install | Front Number Plate Holder | Remote Throttle | Winch Kit | Winch Instructions | Battery

Understanding the DC electric-powered WINCH

4X4ICON.COM 2000-2003  The CD! - Click here for details!

4X4 ICON 2000 - 2003 The CD!

 

Specifications | How to Calculate Winch Loads | Winch Load Calculator (Excel Spread Sheet)

 

Specs

Ultimate Performance Series: 9.5ti
WARN 9.5ti
9.5ti THERMOMETRIC SELF-RECOVERY WINCH

The 9.5ti packs 9500 lbs of pulling capacity into a massive 12.5 lb aluminum die-cast body. The new shape not only looks great, but sheds the elements like no other winch on the market: seals at the key points give extreme-duty water resistance. A Gen II Bosch motor delivers just the right balance between torque and speed. Plus another Warn Industries first - operator feedback - the thermometric indicator gives the operator information about motor temperature during the winching operation.

Watch Video | Manual | Parts List

9.5ti SPECS/PART NUMBERS
Part Number: PN 67550 (12V DC)
Rated Line Pull: 9500 lbs. (4310 kgs.) single-line
Motor: Gen II, Series WoundTM
Remote Control: Remote switch, 12' (3.7m) lead
Geartrain: 3-Stage Planetary
Gear Ratio: 156:1
Lubrication: Aeroshell #17
Clutch (freespooling): Sliding Ring Gear
Brake: Automatic Direct Drive Cone
Drum Diameter/Length: 2.5"/9.0" (6.4cm/23cm)
Weight: 89 lbs. (36.3kgs.)
Wire Rope: 125', 5/16" diameter (30m, 8mm diam.)
Fairlead: Roller
Recommended Battery: 650 CCA minimum for winching
Battery Leads: 2 gauge, 72" (1.83m)
Finish: Chromate with high-gloss powder coat
Nuts/Bolts: PN 39570


12V DC PERFORMANCE SPECS
Line Pull
Lbs.(Kgs.)
Line Speed
FT./min(M/min.)
Motor
Current
Pull by layer
layer/Lbs(Kgs.)
0 62(18.9) 47 amps 1/9500(4313)
2000(910) 16.3(4.97) 160 amps 2/8650(3927)
4000(1810) 11.8(3.60) 230 amps 3/7920(3595)
6000(2720) 9.31(2.84) 305 amps 4/7400(3359)
8000(3630) 7.59(2.31) 370 amps 5/6940(3150)
9500(4310) 6.67(2.03) 425 amps
Above performance specs are based on first layer of drum

WARN 9.5ti

 

Winch Dimensions: 23.1" L. x 6.3" D. x 10.0" H.
(587mm L. x 160mm D. x 254mm H.)
Mounting Bolt Pattern: 10.0" x 4.5" (254mm x 114.3mm)

 

 

Understanding the DC electric-powered WINCH

Specifications | How to Calculate Winch Loads | Winch Load Calculator (Excel Spread Sheet)

Understanding the DC electric-powered WINCH

 Calculating Winch Loads

Total Weight = Vehicle Weight + Load weight

Winch Pull = ( <Slope degrees> * Total Weight /60)

Ground Factor Weight  = Winch Pull * Ground Effect Percentage

Winch Load = Winch Pull + Ground Factor Weight


Example.  Given:

  • Vehicle weight = 4,400 pounds
  • 300 pounds of total load weight
  • winch up a 50 degree slope consisting of shallow mud

Total Weight - 4400 + 300 = 4700

Winch Pull - (50*4700/60) = 3917

Ground Factor Weight - 4,700 * 35% = 1645

Winch Load - 3917 + 1645 = 5562

Ground Effects Percentages

Ground Condition *Effort Required
Pavement    2-4 percent
Grass    8-14 percent
Hard Packed Sand    10-17 percent
Wet Sand    15-20 percent
Gravel    10-20 percent
Soft, Dry Sand    25-30 percent
Shallow Mud    30-35 percent
Deep Mud    40-60 percent
Deep Clay Mud    50-70 percent
* as a percentage of total vehicle weight

Winch Load Calculator (Excel Spread Sheet)

(Right-Click and select "Save Target As..." to download)

Understanding the DC electric-powered WINCH

 

 

 

The winch is new for 2004.

 


Winch Plate | Install | Front Number Plate Holder | Remote Throttle | Winch Kit | Winch Instructions | Battery

Understanding the DC electric-powered WINCH

4X4ICON.COM 2000-2003  The CD! - Click here for details!

4X4 ICON 2000 - 2003 The CD!

 

    

   

WARN | Tomken

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