If your winch cable breaks while you are in the middle of using it, you can carry out a temporary repair. Bear in mind that the wire should then be replaced as soon as possible.
Use a bolt cutter to cut off the damaged ends from the cable then repair it by splicing the cable. This is a similar process that’s used on fiber rope.
The winch cable has been created using six strands, as well as a core. Undo each end of the cable for five complete turns and then seize each of the strands individually by wrapping it in baling wire.
Join the strands together in twos at the ends to create three super strands around the core wire. Cut back the core wire on each half, to the point where all of the six strands are seized together.
Create a standard short splice to join the ends of the two pieces of cable together. You’ll need to use a vice to hold the wrench cable in the correct position. Your wrench cable will now be working at about 80% capacity, so you should bear in mind that you won’t be able to tow such heavy loads as before.
How to replace a winch cable
To replace a winch cable, you will need an adjustable wrench and a new cable. I recommend wearing gloves while working with your winch, especially if your winch cable has broken strands as these can easily cut your hands.
First, remove the old cable, this can be done by putting the winch gear into neutral and allowing it to spool free. Pick up the hook and walk away from the winch until the cable comes out. Alternatively set the winch to the “out” position. You’ll then be able to use the motor to spool the line.
Next, unbolt the cable from the drum. One end of the winch cable will be attached to the drum with a bolt and a washer. Open the bolt using an adjustable wrench and remove both the bolt and the washer. This will allow the cable to fall out off the drum.
Once you’ve removed the cable, you can clean out the drum if it’s dirty. You’ll then be able to attach a new wire cable by threading the bolt through its loop and tightening it. If you want to make your winch extra secure, add a small drop of thread sealant.
Next, spool the new winch cable onto the drum. You can do this by switching the winch to pull in, and this will allow you to rewind the cable around the drum. Make sure that it wraps tightly and neatly around the drum.
Winding in an orderly fashion will help to save space on the winch. It also means that when you pull the cable out again it will come out with ease and without incident. Don’t let the winch cable buckle or wrap over itself.
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