Warn 12XP-S Rescue

[PurpleTJAZ]

I unexpectedly have a new project (the wife is so excited).
A friend’s girl friend borrowed his Ford Super Duty and while she had it decided to kill a VW Passat. I offered to order the parts and help fix it. It came with a factory installed Warn winch 12k and replacement was almost $4k. He asked me to just pull it all out and eliminate the wiring.
So now I have a literally brand new heavy duty series Warn winch with a broken gear housing and spool support housing. He said he pulled 10 feet of rope and ran it back in 3 years ago and that is the extent of the wear. Synthetic rope, Factor 55 end , controller , even owners manual.
So does anyone have suggestions on where to get replacement parts? Looks like Warn has the stuff for$600 or so but me being me…..looking for the parts at the best price I can find.

 

[DuckNut]

Junkyard that also has a smashed up truck that had the dealer installed winch or Warn.

 

[tnjeepguy]

@Blackjack

https://www.warn.com/replacement-parts-for-truck-and-suvs

Looks as if you "only" need # 15 drum support, gear end and # 38 gear housing. Rest looks OK, may need # 35 (see it but can not tell)

Believe any 12k of that series are the same ?? Might be best to try and find a junker and salvage those parts ?? D

https://www.facebook.com/marketplac...wse_serp:be003028-474f-49a8-bb07-ebc629e13a30

 

[PurpleTJAZ]

@Blackjack

https://www.warn.com/replacement-parts-for-truck-and-suvs

Looks as if you "only" need # 15 drum support, gear end and # 38 gear housing. Rest looks OK, may need # 35 (see it but can not tell)

Believe any 12k of that series are the same ?? Might be best to try and find a junker and salvage those parts ?? D

https://www.facebook.com/marketplace/item/916730057306707/?ref=search&referral_code=null&referral_story_type=post&tracking=browse_serp:be003028-474f-49a8-bb07-ebc629e13a30

Yes # 38 runs mostly across the board. This is a HD M12 so the diagram shows #19 and to get that you have to get #9 Which includes both ends and is about $400. I’m still evaluating if this project is worth the investment.

https://www.warn.com/Attachment/DownloadFile?downloadId=1841

 

[tnjeepguy]

blackjack may have one he will sell you. If you use it, you have a 1000 winch for 600-, not bad really.
That one looks as if it has a smaller drum ?? Little husky for a TJ, but not that much weight than a 9.5 with your syn line.

Be on the lookout for a non running 12k that someone is selling cheap. Your motor and other parts are good and can make one good one that is standard size. Be patient. Hard to beat a good used Warn.

https://www.facebook.com/marketplace/item/581446897822377/?ref=search&referral_code=null&referral_story_type=post&tracking=browse_serp:526906fe-9961-44ee-9e87-5261b585c07b

https://www.facebook.com/marketplac...wse_serp:526906fe-9961-44ee-9e87-5261b585c07b

Not 12k but nice Warn's. D

 

[PurpleTJAZ]

I called Warn about this unit to see what I could find out. It is a specialty built winch for Ford for their trucks. It is 2" narrower to allow it to fit between the frame rails and behind the bumper. It has an 8" x 4.5" mounting pattern and a narrower drum requiring an equally narrower fairlead. Fairlead looks to be about the size of the ones you see on a sxs. Other than that it appears to be a cut down M12 winch. Warn offers no replacement parts for this winch and would or could not confirm or deny that any M12 parts would interchange. If I do manage to repair it I will still have to re-drill my Savvy winch mount and modify to accommodate a smaller fairlead.
@Blackjack has generously offered to do a little investigation into it for me so I think I will shelf it for now.

 

[PurpleTJAZ]

i reached out to the Warn sales rep I met at SEMA last year with the information I was given from@Blackjack. I was able to order the parts to put this back together. I guess we’ll see how it goes.

 

[PurpleTJAZ]

I would like to say it only took one try to get it back together but……more like 5or 6.
Anyway back together and ready to test the motor tomorrow.

 

[PurpleTJAZ]

Tested motor successfully runs in and out as it should

Next challenge is mounting the control box.
It is designed to be mounted remotely. Positive and negative cables are eight feet long. Can reach anywhere. Field cables are 20 inches. Not long enough to reach inner fenders.

Connector on top of box has no pins for wiring because again it is designed to be remote.

It is designed to use this proprietary fair lead that has a very narrow bolt pattern.
Kind of cool but not going to happen.

Like most projects, the devil is in The details ….

 

[PurpleTJAZ]

Played around with where to mount control box and I think this is it

Modified the Ford bracket and it’s a pretty nice fit

I will need to build some longer field cables.
I’m going to need some bigger crimpers .

 

[PurpleTJAZ]

I fabricated a bracket to mount control on top of winch. Works ok but still not sure which way to go. Under hood temp get pretty high in AZ and may be detrimental to the controller. I will run it wireless or off the dash switch so access to the box is not a big deal.

 

[macleanflood]

I put my contactor box in that same exact spot under my 97 hood. Zero issues... except for Warn's wireless controller that plugs into the wired port. I left it plugged in...that might have killed it...or the under hood heat... regardless I spent a year fighting with Warn on the warranty...they ultimately said the warranty expired while I waited for them to get parts in stock. So I bought a $15 Amazon wireless winch controller and wired it in. Zero issues works every time.

Haven't cooked a winch motor in a long time...these items help...

-Mac

 

[PurpleTJAZ]

Well it's been awhile since I have had time to update any of my posts but I have some tome now. I finished this project several weeks ago and it turned out pretty darn good.

I ended up mounting the control box under the hood. It was a little more work, but gives it a cleaner look on the grille. Also I will control it wirelessly or from a dash control switch. If needed I can always lift the hood and use the plug in wired control.

Ended up selling the Smittybilt xrc9500 for almost enough to cover all the parts to put this 12k Warn back together. All done and after selling my old winch I think this ended up being a nice upgrade for very few dollars.

 

[DeltaNu1142]

Played around with where to mount control box and I think this is it

I’ve been following this. Thanks for posting the control box install photos. I have my X2O control box mounted under the hood of my F150 because the winch is hidden in the bumper… there’s no clearance for the box.

I’m planning on doing the same for the LJ. The box is more secure and out of the elements under the hood… though, it’s a lot hotter in there. My F150 winch works fine after probably 8 years (half in FL), but the LJ may be hotter under the lid.

 

[PurpleTJAZ]

I’ve been following this. Thanks for posting the control box install photos. I have my X2O control box mounted under the hood of my F150 because the winch is hidden in the bumper… there’s no clearance for the box.

I’m planning on doing the same for the LJ. The box is more secure and out of the elements under the hood… though, it’s a lot hotter in there. My F150 winch works fine after probably 8 years (half in FL), but the LJ may be hotter under the lid.

Well time will tell. It definitely makes for a cleaner look. I would not put it there if I needed to use a wired remote, but I have a wireless controller and also hardwired dash switch. I do carry a wired remote in the tool bag just in case.

 

[DeltaNu1142]

I think I’d still put it under the hood if I needed a wired remote… I’d just put a plug in between and make it accessible somewhere convenient.

(he said from an airport shuttle, 600 miles from being able to verify he could actually do it)

 

[tnjeepguy]

the wife is so excited

Still ??

Hard to beat a Warn.
Good work.

 

[tobiism]

Great score! Nice resto!

 

[PurpleTJAZ]

Great score! Nice resto!

Thanks

 

[MBDIAGMAN]

I put my contactor box in that same exact spot under my 97 hood. Zero issues... except for Warn's wireless controller that plugs into the wired port. I left it plugged in...that might have killed it...or the under hood heat... regardless I spent a year fighting with Warn on the warranty...they ultimately said the warranty expired while I waited for them to get parts in stock. So I bought a $15 Amazon wireless winch controller and wired it in. Zero issues works every time.

Haven't cooked a winch motor in a long time...these items help...

View attachment 596833View attachment 596834

-Mac

Yep, they’re indispensable and it doesn’t appear that you will run out of them any time soon!. Better to have them and not need them than to need them and not have them.