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.

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.

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.

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 TMW-0924-V

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

• 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...

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.

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.

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.

• 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*

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...

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!

Ultimate Performance Series: 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   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

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Understanding the DC electric-powered WINCH