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Unread 07-13-2010, 01:50 AM   #1
danielbuck
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warn m8000, solenoid not assembled completely?

So my M8000 arrived today, and I was mounting the winch to the winch plate in my living room, with plans to mount it all on the jeep this weekend.

I opened up the plastic case that covers up the solenoids because it sounded like there was alot of rattling going on in there, and there were a few wires sticking out of it that didn't feel like they were connected to anything. Sure enough, not much is connected in there.

It looks like quite a few things are not connected properly? None of the copper looking posts have nuts on them to secure the connecting copper pieces to each other (I assume they should?) And I'm not sure where to connect the black main big thick wires (sitting outside the case in the photo). They are labeled on one side (the posts on the winch itself) but on the solenoid side, I'm not sure which wires should be on which posts. The ends of the big wires were just shoved into the box, not connected to anything. And the solenoids are not bolted to the metal part of the case, should they be just free floating inside of there? or are they missing some hardware?

Is this normal, is this how it's supposed to arrive? (it's new, not used) It kinda just looks like it's not finished being put together yet, and I don't see anything in the instructions mentioning the solenoid connections inside the box at all. If this is how it's supposed to arrive, I'm dissapointed. If this is NOT how it's supposed to arrive, I'm still dissapointed. Also dissapointed that there is no mounting bracket for the solenoid box, I guess the old threads that I read are still accurate, warn still does not provide this item in the kit.

I'm glad I opened it up before I started trying to mount it all to the jeep.

I'm gonna call up Warn tomorrow, but figured I'd post up here since the M8000 seems to be a commonly used model.





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Last edited by danielbuck; 07-13-2010 at 02:09 AM..
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Unread 07-13-2010, 07:12 AM   #2
hammerz71
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Yeah, that's not right. Could it be the place you bought it from opened it up at some point to "borrow" a part (solenoid maybe) and just threw one in there when they replaced it?

I bought my M8000 in '05 and other than being rather disappointed that they couldn't include a bracket for the control box (what could it cost them, $2?), it was ready to run by just connecting the power cables...
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Unread 07-13-2010, 02:13 PM   #3
Orca
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Yea ,you can be really dissapointed. A new Wich should be wired completly. Not like yours. But it is interesting for me to see your control box. Ive got a Warn M8000 to, and my control box looks different. I have a small circuit board between my solenoids. This board controls the power between the solenoids for cable in or out.
Did Warn build different control boxes over the years?
But Im sure with a liittle help from Warn, you can wire up your box wthout probs.
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Unread 07-13-2010, 02:21 PM   #4
danielbuck
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I'm going to see if they can just send me a replacement solenoid kit, just because even if I manage to get the wires hooked up where they need to be, how do I know something else isn't missing, or not done properly?
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Unread 07-13-2010, 03:04 PM   #5
BYuen
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Quote:
Originally Posted by danielbuck View Post
I'm going to see if they can just send me a replacement solenoid kit, just because even if I manage to get the wires hooked up where they need to be, how do I know something else isn't missing, or not done properly?
Yea I would definitely ask for a new solenoid assemble/control box that's actually assembled. You shouldn't have to deal with that with a brand new winch out of the box like that. Where did you get the winch from?
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Unread 07-13-2010, 04:19 PM   #6
danielbuck
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Replacement options have been offered to me (both by Warn, and by the company who it was ordered from), so looks like problem is being resolved nice and quick.

Nobody really know what happened though. Warn said that they would not expect any of their products to be shipped like this. Must have been a fluke or something. Oh well, it's being resolved
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Unread 07-30-2010, 12:43 AM   #7
danielbuck
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Ok, finally got the replacement and got it all on there, works like a charm! :-)

I do have a question, how are yall getting the wires into the engine bay? I figured through the radiator grill is probably better than going under the radiator. Found a spot that I could slide the wires through, but they are resting against some metal pieces of the radiator (or rather, the A/C radiator I think?) And there was some slack in the wiring, so i wrapped the wires once around part of the air box.

Is there anything wrong with how i have this setup, or anything that would be better? Later on, I may try and mount the box under the hood for a cleaner look, we'll see. Now that I know it all works, I can always go back and get longer wires and mount it under the hood if I wish.





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Unread 07-30-2010, 01:26 AM   #8
BYuen
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Looks good! I routed my wires underneath the radiator just as you did. Here's what I did after the radiator:

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Unread 07-30-2010, 01:39 AM   #9
danielbuck
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you know, I was thinking about zip tieing them to that support rod, there's just enough slack to do so I think. Maybe I'll do that.
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Unread 07-30-2010, 12:24 PM   #10
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I've got the Warn m8000 as well. I ran my cables under the radiator and along the top of the frame rails. I had heater hose laying around so I ran the wires through the hose so that it wouldn't rub on the cables and cause problems.
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Unread 07-30-2010, 12:49 PM   #11
danielbuck
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that's not a bad idea either, running the cables through some hose. I may do that around the bends coming passed the radiator, if I can get some hose in there. So that they don't possibly rub through the rubber protection around the wires.
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Unread 07-30-2010, 03:07 PM   #12
Jerry Bransford
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Adding some protective plastic wire loom or a short length of rubber heater or garden hose slit up the side over the winch power cabling and held in place by zip ties where it passes through the radiator grill area would be a good idea. I've seen the winch wiring short to ground from rubbing on the grill opening in that area which caused a fire.
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Unread 07-30-2010, 04:56 PM   #13
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yea, I suppose anything could work, so long as it can handle a bit of heat and rubbing. I think I'll do that, thanks for the encouragement Jerry
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Unread 08-02-2010, 12:06 PM   #14
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I re-routed the wires to go under the radiator (there's a nice little gap there, they are almost flush with the bottom of the radiator off to the side) and put some radiator hose around them where they come in contact with other parts of the jeep.

Also use some radiator hose clamps and some small slices of radiator hose to clamp the wires nice and secure (wrapped the wires in about 1 inch of hose, then clamped around that so as not to cut into the wires with the metal clamps), instead of zip ties. I noticed the zip ties have a temperature rating of 175 degrees or so, not sure how long they would last. Thanks again for the suggestions, I think it's perfect now!
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control box , m8000 , solenoid assembly , warn , winch

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