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Winch solenoids

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NCtoy View Drop Down
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    Posted: 17 Nov. 2018 at 8:54am
After a good 15 years of use I finally burned up the original solenoids in my winch a couple years ago. Since then I’ve bought new ones from amazon, both knock off and warn branded ones (who knows if they are actually warn or not). But now it seems like every time I use the winch I burn up a solenoid. The other day one of the “spool out” ones appears to have locked itself in the on position, and when I tried spooling in it burned up my battery post mount. 

I’ve checked the motor by bypassing the solenoids and it’s still good. I can’t find any burned or rubbed bare wires. Anybody else have an idea or is it just junk solenoids? I’m about to order a set of solenoids from Clemson 4wd. They are a warn service center so I would expect to get the real deal from them. 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Spinnas Quote  Post ReplyReply Direct Link To This Post Posted: 17 Nov. 2018 at 8:08pm

Slight long shot, but have you checked resistance on all the wires?

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Post Options Post Options   Thanks (0) Thanks(0)   Quote NCtoy Quote  Post ReplyReply Direct Link To This Post Posted: 19 Nov. 2018 at 12:35pm
On the wires that control the solenoids? No. I’ll try that if I get some time this week. 

The other thing I thought after this post is to disassemble the controller and make sure no wires are broken or touching in there. Maybe a malfunction in there could have it trying to winch in and out at the same time and burned them up?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote 48cj2a Quote  Post ReplyReply Direct Link To This Post Posted: 19 Nov. 2018 at 12:59pm
Be SURE its a "Continuous Duty" solenoid
 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote NCtoy Quote  Post ReplyReply Direct Link To This Post Posted: 31 Dec. 2018 at 5:19pm
An update and a word of caution for anybody else in the same boat. I double checked all the connections, looked at every wire, and found no problems. I then took out the old solenoids and tested them. I found 2 bad ones, one of which was locked in the on position. I them replaced all 4 solenoids with new warn ones. 

If you order solenoids, spend the extra money ordering from a warn dealer and get the real thing. The real warn ones came in a warn logo plastic bag, and have the warn logo embossed or etched into the body of the solenoid. I can’t find real warn solenoids available on Amazon, although several people are selling them advertised as such. 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote JDJeeper Quote  Post ReplyReply Direct Link To This Post Posted: 01 Jan. 2019 at 5:46am
Have you looked into replacing the solenoids with a contactor pack?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote NCtoy Quote  Post ReplyReply Direct Link To This Post Posted: 01 Jan. 2019 at 7:37pm
Never heard of it. My original ones lasted 15 years, I’m hoping it will be a while before I have to replace these.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote cjbilly Quote  Post ReplyReply Direct Link To This Post Posted: 04 Jan. 2019 at 4:15pm
I bought these HD solenoids for my WARN 8274 years ago. Haven't installed yet but understand these are a good replacement. Might be worth looking into.

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Post Options Post Options   Thanks (0) Thanks(0)   Quote duffer Quote  Post ReplyReply Direct Link To This Post Posted: 04 Jan. 2019 at 10:03pm
Originally posted by cjbilly cjbilly wrote:

I bought these HD solenoids for my WARN 8274 years ago. Haven't installed yet but understand these are a good replacement. Might be worth looking into.


I'd be a little cautious using those.  Few, if any, starter solenoids are rated for continuous duty.  And even fewer can handle the near 500 amps an 8274 can pull at stall. 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote cpt logger Quote  Post ReplyReply Direct Link To This Post Posted: 04 Jan. 2019 at 11:36pm
I am with Duffer on this one, you will need continuous duty solenoids for a winch. Look at marine or industrial uses. You will want them to have as high an amp rating as you can afford.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote chasendeer Quote  Post ReplyReply Direct Link To This Post Posted: 05 Jan. 2019 at 12:23am
I had this trouble with my small four wheeler winch. I tried to use car solenoids and they would last one time. Switched them to warn and have had no problems in five years. 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Rick R Quote  Post ReplyReply Direct Link To This Post Posted: 05 Jan. 2019 at 12:27am
I will probably go this way on my 8274

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Post Options Post Options   Thanks (0) Thanks(0)   Quote cjbilly Quote  Post ReplyReply Direct Link To This Post Posted: 07 Jan. 2019 at 9:41am
Originally posted by cjbilly cjbilly wrote:

I bought these HD solenoids for my WARN 8274 years ago. Haven't installed yet but understand these are a good replacement. Might be worth looking into.


Thanks guys for the clarification. Beer

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