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Old November 27th, 2004, 07:47 PM
Joe P's Avatar
Joe P
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Joe Pfeiffer
Black 97 D-90ST #0605
Join Date: Oct 2003
Location: Irvine, CA
Posts: 748
Newbie Winch Question

Got the Warn XD9000i this week and want to use the long weekend to install it. I have everything on the truck, now the tough part. First the cables are too short - surprise the battery is under the seat and not the hood.

Two questions-

First - What did you do to A lengthen the cables or B replace the cables.

Second - How did you route the cables.


If the truck makes it - the trail wasn't tough enough.
If the truck doesn't make it - the truck wasn't tough enough.
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Old November 27th, 2004, 08:03 PM
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Mike Hippert
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94 D-90 Grinding Rover
Join Date: Sep 2003
Location: Manchester NH USA
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Hey Joe, I picked up some longer cables at West Marine, they have heavy gauge wire that is nice and flexible. I am pretty sure they have a way to splice the wires together, or you could get one of those heavy 2 prong connectors, the type they use on forklifts, warn also sells them for there receiver mount winches. That way you can use that point to hook up a pair of jumper cables using the same type of connector and not have to go into the seat compartment.

As far as running the cables, I ran them next to the frame all the way to the T-case mount, from there I ran then up into the seat box and connected them directly to the battery.
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Old November 28th, 2004, 01:30 AM
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Barry O'Mahony
97 D-90 SW LE
Join Date: Dec 2003
Location: Bend, OR
Posts: 281
I don't like splicing cable. The splice is a failure point (it is more likely to fail than the wire itself). Either the connection opens, or the insulation that it put on the splice shorts out (not something you want to happen on an unfused, high-amperage connection direct to the battery).

I got lengths of #1 AWG battery cable at a local NAPA. The terminal ends are not easy to put on; they're a compression fitting that must be crimped on properly. That's the only tricky point.

I ran the cables as Mike did. I'd suggest putting that black plastic wire protective tubing (i.e., the type slit along one side) over the positive cable for extra insurance.

Also, install a cut-out switch in the battery compartment. I understand a common vandalism technique in Australia is to wrap the winch cable over the top of a vehicle and attach it to the rear hitch, and use a couple of paper clips in the winch control socket to turn it on: not a pretty picture.
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