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Winch Not Working? Here’s How to Bypass the Solenoid and Get Back on Track!

An essential part of every winch system is the solenoid. Power is sent from the battery to the winch motor via this component, allowing the winch to haul massive weights. Unfortunately, winch solenoids can wear out or stop working over time, rendering the winch inoperable. This post will explain how to remove the solenoid from a winch so that it can be used again.

Understanding winch solenoid

We need to define what a winch solenoid is and how it functions before we can discuss how to circumvent it. A solenoid is used to regulate the flow of current from the battery to the winch motorhow to circumvent it. A solenoid is used to regulate the flow of current from the battery to the winch motor. A signal from the winch controller is sent to the solenoid, which then shuts down the circuit and supplies power to the winch motor.

Winch solenoids typically have problems like:

Contacts in solenoids are getting stuck or frozen.
Dead solenoid coil
Worsening corrosion on solenoid contacts

Reasons to Bypass the Winch Solenoid

It’s possible to bypass a winch solenoid for a number of reasons. If, for example, the solenoid is broken or malfunctioning and needs to be replaced, you can get by without using it until you can get a new one. Furthermore, bypassing the solenoid may be necessary if one does not have access to a replacement solenoid or if the rapid operation of the winch is required.

Tools Needed to Bypass Winch Solenoid

Now, let’s talk about the equipment that is required in order to bypass the solenoid on a winch. The use of fundamental instruments like screwdrivers, pliers, wire cutters, and strippers is necessary. In addition to that, you will need a certain length of wire as well as some wire connectors.

Winch solenoid bypass techniques

The many ways to avoid using a winch solenoid each have their advantages and disadvantages. Next, we’ll discuss the three most typical approaches.

Method 1: Direct Wiring

Wiring a winch directly means connecting the battery terminals directly to the winch’s motor, skipping the solenoid. Follow these steps to complete the task:

The battery’s negative terminal must be disconnected.
Determine where the winch’s motor and solenoid are located.
Pull the wires away from the solenoid and attach them straight to the winch’s motor.
Connect the battery’s negative terminal back to the battery.

The benefits of direct wiring:

Easily accomplished, requiring little effort.
does not need any other tools or components to function.
This is possible to accomplish in urgent circumstances.

Negatives of direct wiring:

It’s risky since improper installation might result in flames and electrical shocks.
If too much force is applied, the winch motor could be damaged.

Method 2: Using a Bypass Kit

A bypass kit is a series of wires that enables you to connect the battery directly to the winch motor in order to bypass the winch solenoid. How to use a bypass kit is as follows:

The battery’s negative terminal should be disconnected.
One end of the bypass wire should be connected to the battery’s positive terminal.
The positive terminal of the winch motor should receive the other end of the bypass cable.
One end of the ground line should be connected to the battery’s negative terminal.
The winch motor or winch frame should be connected to the opposite end of the ground cable.
Reconnect the battery’s negative terminal.

Advantages of utilizing a bypass kit

Considering that it includes the required cables and connectors, it is safer than direct wiring.
can be applied as a long-term fix for a broken solenoid.
can be quickly disconnected if necessary.

Drawbacks to utilizing a bypass kit

perhaps more costly than direct wiring.
possibly need some understanding of electrical circuitry.

Method 3: Replacing the Winch Solenoid

The solenoid that controls the winch may need to be repaired or replaced if it stops working properly. To change a winch solenoid, do as follows:

The battery’s negative terminal must be disconnected.
Try to find the solenoid for the winch.
Pull the solenoid’s wires out of the wall.
Take the solenoid off its bracket by loosening its mounting nuts.
Connect the wires and the new solenoid.
Connect the battery’s negative terminal back to the battery.

The benefits of a new winch solenoid include:

Ultimately addresses the underlying issue.
It reverts the winch to its factory settings.

Disadvantages of Not Changing the Winch Solenoid:

It costs more since a new solenoid must be bought.
perhaps requiring familiarity with mechanical processes.

Steps to Bypass the Winch Solenoid

As soon as all of the required tools have been obtained, the process of removing the winch solenoid can get underway. In order to prevent the winch motor from receiving power from the battery inadvertently while the process is being performed, the first step is to disconnect the battery.

After that, you need to find the solenoid for the winch. It is typically found in close proximity to the motor of the winch and resembles a little box that is rectangular in shape and has wires connecting to it. If it is not evident where the solenoid is located, studying the winch manual can provide additional information about its placement.

It is recommended to use pliers to remove the wires that are attached to the winch solenoid. While doing so, it is essential to make a mental note of which wires belong in which locations, as the wires will need to be reconnected at a later time.

After that, a piece of wire should be cut to length, and its ends should be stripped using a pair of wire cutters and strippers. The positive terminal on the winch motor should have one end of the wire attached to it, and the positive terminal on the battery should have the other end of the wire linked to it.

It is also necessary to connect the winch remote; therefore, another segment of wire should be taken and its ends stripped. The negative terminal on the winch motor should have one end of the wire attached to it, while the other end of the wire should have the other end linked to the negative terminal on the battery.

After the wires have been linked in the correct manner, the battery may be activated and the winch can be examined. Once everything has been done correctly, the winch should work exactly like it would ordinarily if it were left alone. If, despite your efforts, it is still not functioning properly, there may be an additional problem that requires attention.

If you follow these procedures, you should be able to bypass a winch solenoid with relative ease, despite the fact that the idea behind doing so may be scary. Always remember to remove the battery before doing any work on the winch, and name the cables as they are removed to make it simpler to rejoin them after they have been removed. In addition, be sure that the wire connectors you select are adequate for the wire gauge that is being utilized.

Safety Recommendations

It is critical to take safety precautions when dealing with winches and solenoids to avoid harm or damage. Following are some general safety recommendations:

Always wear protective equipment, such as gloves and eye protection.
Always use the winch with a load attached.
To operate the winch, always use a winch controller.
Never lift or move people with the winch.

Follow these additional safety precautions when bypassing the winch solenoid:

Check that the winch is securely fastened and grounded.
While the wires are linked to the battery, never contact them with your naked hands.
When working with electricity, exercise extreme caution and adhere to all safety precautions.

Finally, bypassing a winch solenoid is easy and can be done using common equipment. You can rapidly get your winch operating again by following the instructions indicated above and taking certain care. Bypassing the winch solenoid is a useful technique to have, whether you’re repairing a damaged solenoid or need to get your winch running quickly.