A winch is an amazing tool to let you explore further with the confidence you need to know you’re able to get yourself or someone else unbogged – but like any tool, it pays to understand what could go wrong with a 4×4 winch, and how to troubleshoot issues. So I’m going to take you through how to easily and quickly diagnose and troubleshoot the most common issues that occur with any electric winch, to get yours working again. Even if you don’t have any of these issues with your 4wd winch, this is great information that could get you out of a jam one day – and if you stick around to the end I’ll let you in on my #1 tip to ensure trouble-free winch operation – and it only takes 5 minutes!

FIRST STEP: CHECK THE BASICS

With any sort of mechanical issue, always check the simplest things first!

If you plug your winch controller in and there’s no response from the winch in either direction or it cuts in and out intermittently, pop the bonnet and check that the winch isolator is in the ON position – I’ve forgotten to do this more than once so don’t feel bad if this solves your problem.

The winch isolator can be removed and cleaned if it doesn’t feel like it is engaging properly as you twist. Disconnect the positive lead from the battery and open by unscrewing both ends of the winch isolator in an anticlockwise direction – be careful when separating the two halves to avoids losing the internal spring. Check nothing has built up inside the winch isolator and it is making a positive connection when engaged.

Next, check for operation of the winch controller. Make sure that the pins aren’t bent or broken, and with a small flat blade screwdriver, very slightly pry them open like this – the same as on a trailer plug. This ensures a proper connection when plugged into the control box. On Domin8r Xtreme winches with a wireless remote, make sure the battery hasn’t gone missing or flat, and replace if necessary.

While you’ve got the bonnet open, check that the connections to your battery are done up tightly by giving them a wiggle. 4wd winches draw a heap of power under load so it’s vital that these connections are done up tightly. If they’re been loose for a while, corrosion may have built up under the terminals. Remove them one by one and sand clean using a bit of sand paper, give it a quick hit of electrical contact cleaner then refit and tighten properly.

Now check the winch operation again to see if this has solved your problem. If not, move onto step two.

STEP TWO: CHECK ALL CONNECTIONS ON WINCH MOTOR

Next, let’s check the connections on the winch motor themselves as over time these can be knocked loose, particularly if you’ve been working in the area adding a driving light wiring harness, or servicing your vehicle.

Because we’re operating in a tight space and using a spanner to tighten the connections, you must disconnect the power to the winch or risk shorting out by accidentally touching another terminal or a metal part of the vehicle.

One by one, pull back the rubber isolator boots and check for cleanliness and tightness of the connection. If the connections are loose or dirty, carefully remove them one by one, clean up with sand paper and contact cleaner, and refit. Make sure you wiggle the isolator boots properly back into position for each connector – and don’t forget about the earth cable that’s typically located on the opposite side of the winch motor to the power cables.

On the Domin8r and Domin8r Xtreme winches, there’s also a small diameter earth cable that goes to the control box – if you remove this make sure to reconnect it, but either way physically inspect to inspect it to make sure that there is no break in the connection. If there is, it must be repaired or the winch control box will not operate.

Once all connections are confirmed as clean and tight, re-connect the winch isolator and check for winch operation again.

FAULT-CHECKING THE CONTROL BOX

With a paperclip you can quickly fault-check your winch control box to check the operation of the winch solenoids. It’s important to note these instructions are for the Domin8r X and Domin8r Xtreme winches, and the terminals I’m about to show you may be different for different brands of winches.

With the winch isolator connected to the ON position again, use a paperclip to momentarily bridge the two terminals next to this small keyway cut-out (where your winch controller plugs in on the control box. You’ll get a small spark and should hear a click as the relay engages, and the 4×4 winch should spool out.

Next, use the paperclip to bridge the two terminals across the top next to the small arrow mark. Again, you’ll get a small spark, hear the relay engage and the 4wd winch should then spool out.  

If the control box and winch don’t respond the right way, it points to an issue inside the winch control box. Because these are mounted right at the front of your vehicle they are subject to mud, dirt and debris, and often the issue is as simple as removing the control box cover and cleaning with sand paper and contact cleaner.

Before removing the control box, once again disconnect the winch isolator. Then, unbolt the control box from its mounting location and you’ll  be able to access the screws on the rear. Undo them and you can separate the housing from the winch control box – however it will still be connected via the wiring.

Using contact cleaner and sand paper, give all accessible connections a good clean and re-tighten, and then give the entire assembly a spray of contact cleaner before re-assembling, refitting to your vehicle and connecting

FIVE MINUTE SERVICE TO SAVE YOUR WINCH

Here’s the simplest tip you’ll ever learn, to ensure your 4wd winch stays in good operation!

After every 4WD trip, or once a month when you wash your vehicle, spool your winch all the way out with at least one full wrap on the winch drum and then spool it back in under tension. This gets the motor and gearbox turning over, gets it warmed up and prevents things from getting stuck through non-use.

When spooling back in, use some sort of tension as you wind the rope back in. The easiest way is to connect to a solid anchor point and winch slighting up-hill, using the weight of the vehicle as the tension.

This also gives you an opportunity to inspect the winch rope for damage, and as long as you’re winching in a straight line, will ensure the rope is neat and can be unspooled easily the next time you need it.