Warn Contactor Solenoid Upgrade

[coleman02]

Hello,
I recently inherited a 02 or 03 TJ. My dad had hit a deer with it and I’m in the process of fixing it up.
As part of the parts I bought for repairing the deer damage, I got an older Warn bumper and XD9 winch. The winch isn’t working currently. I tested the winch motor by applying power directly to the motor connections, it spools both ways. I’m assuming theres an issue with the solenoid box. It’s pretty rusty I’d guess that I either have a bad solenoid or a bad connection somewhere.
I was going to troubleshoot the solenoid box but I noticed the contactor upgrade kits. I’m thinking this might be a better solution to the old solenoid box?
There is 2 different kits I can find. One is Warn part #99760 and the other is #83664.
Looks like #99760 is discontinued but is still available in Canada for 300$ whereas the #83664 is 372$.
I’m wondering if anyone has experience with the upgrade kit?

 

[flyinfish]

@Blackjack will be able to answer your question.

 

[Blackjack]

Hello,
I recently inherited a 02 or 03 TJ. My dad had hit a deer with it and I’m in the process of fixing it up.
As part of the parts I bought for repairing the deer damage, I got an older Warn bumper and XD9 winch. The winch isn’t working currently. I tested the winch motor by applying power directly to the motor connections, it spools both ways. I’m assuming theres an issue with the solenoid box. It’s pretty rusty I’d guess that I either have a bad solenoid or a bad connection somewhere.
I was going to troubleshoot the solenoid box but I noticed the contactor upgrade kits. I’m thinking this might be a better solution to the old solenoid box?
There is 2 different kits I can find. One is Warn part #99760 and the other is #83664.
Looks like #99760 is discontinued but is still available in Canada for 300$ whereas the #83664 is 372$.
I’m wondering if anyone has experience with the upgrade kit?

Both do the exact same job the 99760 is just more elegant in doing it IMO.

 

[Jerry Bransford]

Pull the cover off the solenoid enclosure, check the connections at the solenoids, make sure the wiring looks good.

This is from a good troubleshooting page I found years ago.

Quote:
The WARN P/N is 28396 and can be found under a few more numbers too:

• Prestolite#SAZ-4201EY
• 15-487 (this is occasionally found in boat shops as a starter solenoid - edit)
• 440262
• 546-033
• 1231A
• WS487

Individually the solenoids look like this:

WARN's "i" winches use qty=4 top-terminal solenoids that slide into a rail that's under that top cover — They're a bit of a PITA to get out, but... they all replace easily enough... The solenoids are used in "pairs" so it takes qty=2 for "IN" and qty=2 for "OUT", and if one goes out the winch won't turn and you get to hear the 'other' working solenoid for that direction "click", like you're describing.

The fix is easy... with things still connected to power — pull the cover, attach your remote and make the solenoid 'clicky noise'... you'll be able to hear which solenoid is clicking (for your "IN")... with that — chase the small control wire (like the "key to start" wire on a starter solenoid). to the other solenoid that should be "turning on" — disconnect that wire at the 'bad' solenoid... AND to be certain that you've disconnected the correct wire — re-verify that you can still make the "solenoid clicky sound" for your "IN" and that "OUT" still is fully functional.

That's as far as you wanna go with power on — Disconnect ALL power at the battery so you're not learning welding too!

Then it's all about dissection to remove the one bad solenoid and swap in the replacement. The high-current stuff will be handled by copper straps... sometimes numbering them before you start is handy! — I always go through the trouble of cleaning the contact area and applying a conductive grease (Like Alox or ALGuard) to help assure that I will always have tug!

BIG HINT: if you've got a digital or other camera — TAKE PICURES OF THAT MESS BEFORE YOU START removing a bunch of wires... you will need to put em back together...

The schematic(kinda) look for the 9000i solenoid pack is a lot like this one (this is for the 3-wire early remote, but the solenoids are the same - primary difference is that the ground is also switching through the remote in the 5-wire version):

This pic also talks about how to add a wired remote; that's the stuff on the left edge with the nomenclature "remote switch wire"

Huge image of what you can expect under the cover (again a 3-wire model and this has the aforementioned wired remote already rigged to it)

This is a link to a larger schematic... if you need something to print and look at. maybe??... http://www.pajero4x4.ru/winch/8274schematic.jpg

(end of quote)

Personally I would just replace the bad solenoid, I have bought a few solenoids for Warn winches from https://www.dbelectrical.com/solenoids/winch-golf-cart/ and they never had a problem.

Finally, after my current Warn winch's motor burned up from having installed too long of a screw which caused bits of metal to find their way into the motor, I sent it off to Warn who replaced the motor at no charge.... pretty good considering the problem was not caused by them. They also upgraded my solenoid box to a new contactor assembly. That was great but I really don't see any difference or benefit to me with the new contactor assembly over the older solenoid box.