winch wiring question(s)

[tj_od]

I'm attempting to replace the broken, original winch on my Response before the temps settle in below freezing. Tried to replace only the motor (which has a big crack in the magnet) but the x2 (if that's what it is... any identifiers have long been weathered/rubbed off) isn't the same anymore. Thought I had the right replacement motor but no, so I opted to put a brand new terra45 on.

So, the new winch has thicker gauge wires from the battery to the solenoid and the positive runs through a separate circuit breaker first. Also I'm supposed to patch the rocker switch into my keyed ignition wire(?) When I trace the wires from the ignition it's not a single line but rather several. My question(s):

1. Do I just use the two wires that ran from my original toggle switch on the "dash," and run them to the new solenoid or should I follow the installation guide (and if so, does anyone have a wiring diagram particularly for the keyed ignition, or have a link to where I can get one... and how the heck do you see what's going on behind the dash anyway) and use the rocker switch that came in the box, bolted on someplace else.

2. Am I flirting with catastrophe to use the original power lines (slightly smaller gauge than the NIB wires) from the battery w/out using the included circuit breaker (...because I'm lazy and don't want to find a home for the circuit breaker, or spend more time on this than absolutely needed 'cause I usually need to get my 5yr old snacks or read books with her whenever I have "free time")

3. Do I bother with installing the remote hand-held socket connection (also supposed to have a wire patched into the ignition line). Anyone who winches ever use that?

Thanks for any advice.

[trevorakm1]

i just instaled a superwinch to my bigfoot. as far as the ignition goes, on mine there was a prong on the ignition that was empty and i just hooked to that. it was the red wire from the control switch that ran to the ignition. i did install the handheld remote outlet as my dash had one cut in at one time. it was the only slightly confusing part of the wiring. the red line on mine that went to the ignition was actually both the rocker control switch and the remote outlet wired together and then to ignition. i had to go to autozone to get a connector for the ignition though.
hope this helps some.

trevor

[JohnF]

smaller gauge wire has higher resistance. This can cut into the power at the winch or heat the wires to flames. Without knowing specifics it's hard to have much of an opinion but in your project swapping out the power wires and including the circuit breaker would probably be one of the first bits I would do. Using a small piece of heavy brass strap I have mounted circuit breakers right at the battery post. There has to be clearance for this and consider some sort of cover/protection against accidentaliy touching with a wrench (I've seen that before ).

I imagine using the toggle you already have would work fine. I would try it.

The remote connector can be added at a later time. There are many times when that can be handy. One time I can imagine is when you have to sit at the toggle and look up and see that the pull is directly away from you and then you realize that should that cable break... Not good. With the remote you can stand to the side.

[tj_od]

Took the advice thanks! and ran the new, thicker cables, zip-tied the circuit breaker up out of the way. Replaced the mangled battery post clamps (my argo has a car battery). Used the toggle switch that was already there after swapping out the old circle terminals for female terminals on the solenoid end. Decided to not wire in the hand-held, wired remote as I didn't feel like drilling a new hole (and have other things to get to). I'm going to keep the remote socket and controller in the argo though as I added in some double pronged terminal adapters (which were stock on the wires with the rocker switch that came with the winch that I opted not to use) and could hook it up by opening the hood, if I should need it. Thanks for the help!