Installing a Winch on a Work Truck A do-it-yourself project from DIY Network's Car Care & Repair series: installing a winch on a work truck.

A winch is considered a must-have by many off-roaders. This heavy-duty accessory has helped many a cross-country trekker out of a messy situation. Figure A Figure B If you're serious about off-roading, a winch is one of the best investments you can make. It mounts on the vehicle, anchored to the frame, and uses a motorized drum that spools and unspools a heavy-duty cable. In the event that you become stuck, the end of that cable can be secured to a large tree or rock and the winch engaged to help pull you out. You can also use it to pull someone else's vehicle out of a messy situation, using your own vehicle as the anchor. Electric winches are classified by duty ratings that are based on line pull, gearing systems and size of the motor. When selecting one, consider the size of your vehicle and the type of work you'll want the winch to do. Also consider some of the available options. Some are housed in a removable cradle (figure A) and can be easily removed for storage when not needed. Another benefit of these is that since they attach using a standard trailer-hitch style receiver and hitch-pin (figure B), they can readily be moved from the front of the vehicle to the rear, provided you have the necessary mounting receivers. In this demonstration, we installed a winch to an existing front brush-guard that is constructed with a winch-mount cross member. Materials: Electric winch, wiring and installation hardware Screwdriver Electric drill Wire cutters Since this project involves some work with electrical wiring, the first step is to disconnect the negative battery cable before you begin. Figure C Figure D Figure E Figure F Figure G With a locking hitch-pin your winch cannot be removed from your vehicle without a key. This winch attaches to the auto battery for its power source by means of cables with quick-connectors (figure C) so that it can easily be unplugged when it's removed or relocated from front to back. Before installing the winch, install the cable by running it along the vehicle frame and securing it in place with plastic ties. Be sure to leave enough slack at each end so that you can easily access the connector when plugging in. If you like, you can secure the plastic connectors themselves to the frame with screws. A power-interrupt solenoid will need to be mounted in the engine compartment to control the amount of current running through the electrical connectors. Since this winch is wired so that power is supplied to it only when the vehicle ignition is on, in addition to regulating the current supplied to the winch the solenoid prevents power from running to the winch when it's not in use. This prevents running down of the vehicle battery. The solenoid attaches to the firewall (figure D) using two mounting screws. The ground wire for the solenoid can be attached to the firewall as well. Tip: Whenever you drill into the metal body of a vehicle for mounting-screws or bolts -- such as in mounting the solenoid -- use silicone in the hole or on the bolt-head to seal against rust. Once the solenoid is mounted, you'll need to hook up the power connectors and run the wires for the winch switch inside the passenger compartment. Run the wiring for the switch through a grommet in the firewall so that they are located in an area of the dash that will be convenient for installing the switch. For wiring the switch, there are three separate, color-coded wires (figure E). One leads to a ground, one to the switched ("hot") side of the ignition and the third to the solenoid. With it wired in this fashion, the winch can only be operated with the vehicle ignition on and the winch-switch in the "on" position. The switch can be mounted in a convenient spot that's easily reached on the dash, or under the dash such as on the forward portion of the center console (figure F). With the solenoid mounted, and the interior switch wired and mounted, connect the solenoid to the battery, then reconnect the negative battery cable. You are now ready to test the winch (figure G). If you decide to purchase and install a winch, you may want to consider also purchasing an accessory kit that includes such items as gloves, a tree-trunk protector, a choker chain for dragging heavy cargo, etc. Another valuable accessory is a locking hitch pin to prevent theft of your winch. Return to Road Gear Home Page.