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Power-Out
1. Move switch to the power-out position.
2. Check for continuity between pins (1) and (4).
3. Check for continuity between pins (2) and (5).
Power-In
1. Move switch to the power-in position.
2. Check for continuity between pins (1) and (4).
3. Check for continuity between pins (2) and (3).
2. If there is no continuity, then the remote switch is bad and needs to be replaced.
Thermal Switch Test
The motor will not power-in if the thermal switch is open or if its terminalsare in contact with the motor case. The
switch should normally open when the temperature at the motor brushes reaches 205+°C (400+°F).
If the Thermal Switch is suspected to be failing check the following:
1. Disconnect the switch.
2. Measure the resistance of the switch at the electrical connector.
3. If the switch is open at room temperature then replace the motor.
4. If the switch is closed then the switch is good.
5. Check for resistance between both terminals and the motor case.
6. If the resistance is less than 1 megaohm then the winch is grounded. Replace the motor (Refer to 23 - BODY/
WINCH/MOTOR - REMOVAL).
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Low Voltage Interrupt (LVI) Test
If the LVI is suspected to be failing check the following:
1. Check to make sure the battery has 10.5 to 12 volts.
2. If low, charge battery.
3. Wait for 30 seconds or more.
4. Check for a ground on pin 4.
5. If no ground then check control ground Relay Pack Test .
6. If ground good then replace the relay pack (Refer to 23 - BODY/WINCH/RELAYPACK-REMOVAL).
Motor Test
If the motor is suspected to be failing check the following:
1. Disconnect the motor power connectors F1, F2 and A.
2. Measure the resistance between F1 and F2. Resistance should be less than1
.
3. Measure the resistance between A and ground. Resistance should be less than 1
.
4. If the resistance is greater than 1
the motor brushes could be worn or the internal wiring could be burned.
Replace the motor (Refer to 23 - BODY/WINCH/MOTOR - REMOVAL).
Power Test
1. Check for a tight fit of all connections.
2. Using a volt meter, verify 12 ± 2 volts a the bus bar connecting relays #1 and#3.
Motor Ground Test
1. Check for continuity between the ground stud and the battery.
2. If no continuity then repair the ground cable from the batter to the motor.
Relay Pack Test
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Measurement
between pinsResistance Voltage
Results Correction
(V)
“4” to “5” 2 - Yes Relay pack OK.
No 1. Check for any faulty relay or
motor electrical connections and
repair if necessary.
2. Check for a faulty relay and
replace as necessary. Refer to
Relay Test .
“4” to “2” 2 - Yes Relay pack OK.
No 1. Check for any faulty relay or
motor electrical connections and
repair if necessary.
2. Check for a faulty relay and
replace as necessary. Refer to
Relay Test .
“1” to “2”
100K - Yes Relay pack OK.
No Check for shorted Thermal Switch.
Refer to Thermal Switch Test .
“1” to “3” - 12 Yes Relay pack OK.
No 1. Check for any faulty relay or
motor electrical connections and
repair if necessary.
2. Check for faulty LVI, Refer to
Low Voltage Interrupt (LVI) Test .
REMOVAL
1. Disconnect and isolate battery negative (3) and
positive (1) cables.
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2. Remove the winch support bolts (1).
3. Remove the lower frame bracket (2) bolts (6) and
loosen the upper bolts (1).
4. Support the winch using a jack or other suitable lift
device.
5. Lift the winch assembly off the support brackets.
6. Pivot the frame support brackets (2) up and posi-
tion out of the way.
7. Carefully lower the winch assembly out of the
vehicle.
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8. Remove the nut and disconnect the ground cable
(1) from the motor (2).
9. Disconnect the three cables connected to the
motor on the studs marked F1 (2) , F2 (1) and A
(3).
10. Disconnect the thermal switch electrical
connector.
11. Remove the clamps (2) and separate the coil pack
from the motor.
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12. Remove the four winch mounting and roller
bracket bolts (3).
13. Separate the mounting bracket assembly (1) from
the winch assembly.
INSTALLATION
1. Position the winch (2) onto the support bracket (1)
and install the bolts (3).
2. Tighten the bolts to 108 Nꞏm (80 ft. lbs.)
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3. Position the relay pack onto the motor and tighten
thebandclamps(2).
4. Connect the thermal switch electrical connector.
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5. Connect the three cables connected to the motor
on the studs marked F1 (2) , F2 (1) and A (3).
6. Tighten the nuts to 7 Nꞏm (60 in. lbs.).
7. Install the ground cable and install the bolt (1).
8. Tighten the bolt to 14 Nꞏm (10 ft. lbs.).
9. Raise the winch assembly into position.
10. Pivot the frame support brackets (2) down under
the winch mounting bracket (1).