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5. Install the support bracket (1) and install the bolts
(3).
6. Tighten the bolts to 108 Nꞏm (80 ft. lbs.).
7. Position the wire rope through the roller opening
and install the roller (4), shaft (3) and clip (1).
8. Install the winch assembly (2). (Refer to 23 -
BODY/WINCH - INSTALLATION)
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MOTOR-TIE RODS
REMOVAL
1. Remove the winch assembly. (Refer to 23 - BODY/WINCH - REMOVAL)
2. Remove the bolts and remove the damaged tie rod(s).
INSTALLATION
1. Install the tie rod(s) and install the bolts.
2. Tighten the bolts to 23 Nꞏm (17 ft. lbs.).
3. Install the winch assembly. (Refer to 23 - BODY/WINCH - INSTALLATION)
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RELAY
REMOVAL
1. Remove the relay pack (1). (Refer to 23 - BODY/
WINCH/RELAY PACK - REMOVAL)
2. Remove the nuts (2 & 3), disconnect the cables
and remove the bus straps (4).
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NOTE: Relay #4 shown, all others similar.
3. Remove the nuts (1) and disconnect the control
wires (2).
4. Slide the relay (1) out of the retaining tab (2) and
remove.
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INSTALLATION
NOTE: Relay #4 shown, all others similar.
1. Slide the relay (1) into the retaining tab (2).
2. Install the control wires (2) and install the nuts (1).
3. Tighten the nuts to 3 Nꞏm (25 in. lbs.).
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4. Install the bus straps (4) and connect the cables.
5. Install the nuts (2 & 3) and tighten to 9.5 Nꞏm (85
in. lbs.).
6. Install the relay pack (1). (Refer to 23 - BODY/
WINCH/RELAY PACK - INSTALLATION)
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RELAY PACK
DESCRIPTION
Electrical operation of the control assembly consists of four heavy duty relays, a thermal-switch located on the motor
armature brush holder and a Low Voltage Interrupt (LVI) located in the control assembly. The thermal-switch inter-
rupts the power-in function and the LVI affects both the power-in and power-out functions and must be reset by
allowing the charging circuit voltage to rise above 10 volts for more than 30 seconds. The thermal switch is reset
only by allowing the winch motor to cool adequately (about 30 minutes). Relay number 1 and 3 control current flow
through the field windings and relay number 2 and 4 supply current to the motor armature.
Operation
In the power-out mode, relay number 2 and 3 are energized by the remote control switch. Current flows from the
positive battery terminal through relay number 3 then through the black motor cable to the number 2 and number 1
field windings. From the black motor cable current then flows through solenoid number 2 to the motor armature to
ground.
RELAY PACK
1-RELAY#1
2-RELAY#2
3-RELAY#3
4-RELAY#4F2 - FIELD #2 LEAD
F1 - FIELD #1 LEAD
A - ARMATURE LEAD
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In power-in mode, relay number 1 and 4 are energized. Current again flows from the battery positive cable, but this
time current flows through solenoid number 1 then through field winding number 1. Current flowing in the reverse
direction through the field windings cause the motor to turn in the opposite direction. From the red motor cable
current then flows through relay number 4 to the black cable going to the motor armature to ground.
REMOVAL
1. Disconnect and isolate battery negative cable (3).
2. Remove the winch assembly (2). (Refer to 23 -
BODY/WINCH - REMOVAL)