Winch Assembly
Relay Pack TestREMOVAL
1. Disconnect and isolate battery negative (3) and positive (1) cables.
2. Remove the winch support bolts (1).
3. Remove the lower frame bracket (2) bolts (6) and loosen the upper bolts (1).
4. Support the winch using a jack or other suitable lift device.
5. Lift the winch assembly off the support brackets.
6. Pivot the frame support brackets (2) up and position out of the way.
7. Carefully lower the winch assembly out of the vehicle.
8. Remove the nut and disconnect the ground cable (1) from the motor (2).
9. Disconnect the three cables connected to the motor on the studs marked F1 (2) , F2 (1) and A (3).
10. Disconnect the thermal switch electrical connector.
11. Remove the clamps (2) and separate the coil pack from the motor.
12. Remove the four winch mounting and roller bracket bolts (3).
13. Separate the mounting bracket assembly (1) from the winch assembly.
INSTALLATION
1. Position the winch (2) onto the support bracket (1) and install the bolts (3).
2. Tighten the bolts to 108 N.m (80 ft.lbs.)
3. Position the relay pack onto the motor and tighten the band clamps (2).
4. Connect the thermal switch electrical connector.
5. Connect the three cables connected to the motor on the studs marked F1 (2) , F2 (1) and A (3).
6. Tighten the nuts to 7 N.m (60 in.lbs.).
7. Install the ground cable and install the bolt (1).
8. Tighten the bolt to 14 N.m (10 ft.lbs.).
9. Raise the winch assembly into position.
10. Pivot the frame support brackets (2) down under the winch mounting bracket (1).
11. Install the lower frame bracket bolt (6) and nut (4).
12. Check and adjust the bumper alignment as necessary.
13. Tighten the bolts and nuts to 95 N.m (70 ft.lbs.).
14. Install the winch mounting bolts (1) and tighten to 41 N.m (30 ft.lbs.)
15. Connect battery negative cable (3).
16. Verify the operation of the winch.