Winched [updated]

Hey O&E...what do we know about winches?

This particular example is a Ramsey REP 8000. My parents had it fitted to their 80 series back in 1993.

When the 80 was replaced by the Patrol CC in 2002...the winch was removed with the intention of putting it on the Patrol. That got as far as sourcing a bullbar with a winch mount...

So this winch has not operated at all in the last 16 years...until today. I removed the crusty old winch cable, wired it up on the bench according to the Ramsey manual...and got nothing. Disconnected it and checked the motor by connecting it direct to the battery. Working. Oh good. Cleaned up the contacts on the controller switch plug. Reconnected the lot and...working!!!

As you can see...it’s a crusty looking thing. It was probably put away wet and it spent the downtime in a humid shed. But it works. Question is...what else might it need?

Ramsey just say run the motor occasionally and that the gearbox is sufficiently loaded with lithium grease to last a lifetime. That’s not that helpful. However, it may well be true. Any ideas?

Clearly it needs a new cable. I am considering synthetic rope instead but this is one of those winches where heat is dissipated by loading the cable drum and heat is the enemy of synthetic rope. How do I get around this? Backing rope or tape of some kind? Or just go with wire again?

Update: Gearbox has to come off and be rotated as the clutch switch fouls on the winch carrier that fits the bullbar...so while I’m in there I may add some lube...

Edited: had to gut the gearbox to change the clutch switch location. Lithium grease is super sticky stuff!

Anyway...it’s sorted. Hopefully.

Still needs a new fairlead and, of course, cable. 

Before this can go on... something else has to be sorted.

This Tough Dog kit (or one much like it) is going under it hopefully next week...plus a new steering damper and greasable pins and shackles for the leaf springs. The kit is specced for a bullbar and winch up front plus a constant 500 kg load (bar, winch, steel tray + tipper kit). That should sort out its wayward manners on road and trail. My only concern is that it provides a nominal 2" lift over stock and that tray is already pretty high.