Warn XD9000 Lies Dead in My ARB. - Page 2

Heartless · 10-23-2009, 12:04 AM

Quote:

Before you go buying parts blindly, have you tried manually jumping the solenoids?

yeah, thats probably a good call. However the remote and plug look bunk, and i would not want them out in the bush in their condition. I guess 18-20 AWG are suitable guage for jumpers??

Heartless · 10-23-2009, 01:30 AM

Here's the goods finally. Should i post this as a new thread?

MarcM · 10-25-2009, 10:09 AM

The timing of this thread is fortunate for me. I too have a dormant XD9000 weighing down the front of my Jeep. I bought it used and it is about 15 years old. The seller did the "jumper cable test" when I bought it, and it fired up no problem. After I got it home and mounted, I would not work. Seeing as I have little to no mechanical skill, I had a friend of mine check it out. He said it looks like the solenoids are no longer good. Unfortunately for me, after a call to Warn, I have found out that the replacement solenoids for my particular winch are no longer made, and that I will need to buy a whole new control pack. Before I spend that money, I will use the schematic to make sure everything is wired properly (I mean my friend will...) Again, thanks for the schematic.

**Jerry Bransford** · 10-25-2009, 12:29 PM

Take a pic of your solenoids... I can't imagine them being so old that replacements are not readily available in the aftermarket. Also, I seriously doubt all of them went bad at once... there are four solenoids and the odds of all four being bad are just about zilch. If you ever get down to the San Diego area, I'm betting we could figure out the problem in under an hour.

Heartless · 10-25-2009, 10:18 PM

Quote:

He said it looks like the solenoids are no longer good.

Correct me if im wrong Guru's but im under the impression 2 Solenoids are for forward operation and 2 are for reverse operation. Funny all 4 went at once? Have him double check maybe....

**Jerry Bransford** · 10-26-2009, 01:28 AM

Quote:

Originally Posted by Heartless

Correct me if im wrong Guru's but im under the impression 2 Solenoids are for forward operation and 2 are for reverse operation. Funny all 4 went at once? Have him double check maybe....

X2, that's pretty much what I said above...

Heartless · 10-28-2009, 11:40 PM

The Winch has life... at last. I bought a new Plug, and a new Remote. Both were of the 5 pin variety and under the direction of the Warn dealer i bought the whole kit. I wired it up and jumpered the case to a ground and it was alive... Frankly it startled me but i was happy...

So i have a few more questions before i can let this thread die... I emailed Aaron from Warn and he helped me huge with the wiring diagrams; which may i just say i was correct on... but i guess the problem all along was faulty remote and plug. So. The question is : Can i use a 5 pin plug on the older wich Solenoids like pictured above? I mean it worked in my driveway in and out a foot or two but is it going to work propperly if i wire the extra brown to the empty pins?

Heartless · 10-28-2009, 11:59 PM

This is what i cooked up. It works.

**mark02tj** · 10-31-2009, 02:09 PM

Check the old handheld remote with with a continuity checker. One of the three wires is your ground. The other two are for forward and reverse. Hold the terminals of your continuity checker and have someone else flip the switch on the remote back and forth. You should have continuity between one of the wires and each of the other two. (I wish I could explain this better!!

)

Also make sure that the wires coming from the remote aren't dirty / corroded. I had to clean mine up with a knife blade.

If the remote seems to work, you'll need to check to make sure that you're getting continuity between where the remote plugs into the control box and the other side of those wires. They are very thin and sometimes break. I had to clean the insides with a paper clip.

If all that is OK, check to see if you're getting power to the #1 connection in your drawing above. You should have power to that if your remote is hooked up and you flip the switch for either forward or reverse.

I went through all of this about 10 months ago! Not fun but I finally figured it out. After it was all said and done I could have almost bought a new Warn M8000 WITH A WARRANTY!!

**Jerry Bransford** · 10-31-2009, 05:26 PM

The 5-wire remote only varies from the 3-wire by the addition of the two wires that control the ground for the solenoids in the newer winches. It should work fine on the older 3-wire style winches.

MarcM · 11-01-2009, 09:18 PM

Thank you for the advice. Having looked at the wiring diagram above, it appears that I have overlooked the ground wire. I will have to take a look at the solenoid pack again when I get home to be sure. I think I will also clean the connections as well. It has to be something with the wiring.

And Jerry, thank you for the kind offer!

MarcM · 11-01-2009, 09:26 PM

Oh yeah, what gage wire to use for the ground? 10, 12...?

Heartless · 11-02-2009, 12:41 AM

Off the top of my head i think 16-18AWG, its just the same guage as the rest of the thin ones.

MarcM · 11-05-2009, 02:54 PM

With the help of Heartless's diagram and the advice of numerous people, today I took my solenoid pack off, cleaned all the connection points, made sure any exposed wire was taped, ran a ground wire from the bottom of the solenoid tray to the neg post on the battery, and put everything back together exactly as it shows on the diagram. My winch is alive!

I am a happy guy!

Heartless · 11-06-2009, 11:29 AM

Good to hear man. Its frustrating living with a dead winch as you know... Are you investing in a wireless controller? check it out. That will be my next mogul; but i think i'll wait until spring....