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11. Install the lower frame bracket bolt (6) and nut (4).
12. Check and adjust the bumper alignment as nec-
essary (Refer to 23 - BODY/BODY STRUCTURE/
GAP AND FLUSH - SPECIFICATIONS).
13. Tighten the bolts and nuts to 95 Nꞏm (70 ft. lbs.).
14. Install the winch mounting bolts (1) and tighten to
41 Nꞏm (30 ft. lbs.)
15. Connect battery negative cable (3).
16. Verify the operation of the winch.
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BRACKETS
REMOVAL
1. Remove the winch (2). (Refer to 23 - BODY/
WINCH - REMOVAL)
2. Remove the upper bolts (1) and remove the frame
brackets (2).
3. Separate one of the roller shaft clips (1), remove
the shaft (3) and the roller (4).
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4. Remove the bolts (3) and separate the support
bracket (1) from the winch assembly (2).
INSTALLATION
1. Install 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 wire rope through the roller opening
and install the roller (4), shaft (3) and clip (1).
4. Install the frame bracket (2) and install the upper
bolt (1) and nut (4) and hand tighten.
5. Install the winch (2). (Refer to 23 - BODY/WINCH -
INSTALLATION)
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MOTOR
DESCRIPTION
The winch is driven on one end by a two direction
electric motor powered by the vehicle electrical sys-
tem. The motor is internally protected by a thermal
switch that is activated when the motor gets too hot to
operate efficiently.
Winch motor controls consist of a relay pack mounted
to the motor, and a remote control connected to the
relay pack with a cord. The winch power source
cables are connected to the relay pack which in turn
feeds power to the winch motor through electrical
cable connections. The main function of the relay pack
is to allow the operator to switch the winch on and off
in both directions. The winch relay pack also includes
a Low Voltage Interrupt (LVI) used to prevent winch
operation in the event of battery power dropping below
10 volts.
REMOVAL
1. Remove the winch assembly (2). (Refer to 23 -
BODY/WINCH - REMOVAL)
MOTOR
1 - ARMATURE STUD/NUT 7 Nꞏm (60 in. lbs.)
2-MOTORBOLTS(2)9Nꞏm(82in.lbs.)
3 - MOUNTING BAND CLAMPS
4 - GROUND CABLE
5 - GROUND BOLT 14 Nꞏm (10 ft. lbs.)
6 - MOTOR COUPLER
7 - MOTOR DRIVE SHAFT
8 - FIELD STUDS/NUTS 7 Nꞏm (60 in. lbs.)
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2. Separate one of the roller shaft clips (1), remove
the shaft (3) and the roller (4).
3. Remove the bolts (3) and separate the support
bracket (1) from the winch assembly (2).
4. Remove the relay pack (1). (Refer to 23 - BODY/
WINCH/RELAY PACK - REMOVAL)
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5. Stand winch assembly on the clutch end with the
motoruptomakeiteasiertoalignthemotorcou-
pler and drive shaft.
6. Remove the two motor mounting bolts (1) and
carefully lift the motor (2) off of the drum assembly.
INSTALLATION
1. With the winch assembly (1) standing on the clutch
side verify that the motor coupler (2) is centered in
the drive shaft opening (3).
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2. Position the motor drive shaft into the motor cou-
pler splines and install the motor (2).
3. Install the bolts (1) and tighten to 9 Nꞏm (82 in.
lbs.).
4. Install the relay pack (1). (Refer to 23 - BODY/
WINCH/RELAY PACK - INSTALLATION)