Winch Troubleshooting: How to Figure Out Why Your Winch Isn't Working
A winch that suddenly stops working is a serious headache, especially if you're bogged in the middle of nowhere. Whether you're dealing with a dead motor, a faulty solenoid, or something simple like a loose wire, this universal guide will help you troubleshoot your 12V electric winch and get things moving again.
This guide applies to most popular winches, including models from Warn, Runva, Carbon Offroad, and others. If you’ve got a steel cable or synthetic rope winch and it’s not working properly, start here before calling it quits.
Step 1: Do a Quick Visual Inspection
Before grabbing any tools, take a few minutes to inspect your setup. Many winch issues come down to poor connections or obvious physical damage.
- Check all wiring for signs of corrosion, fraying, or loose terminals.
- Inspect the battery terminals and winch power leads.
- Make sure the clutch lever is engaged (not in free spool).
- Check the ground connection at both the winch and battery.
Step 2: Test the Battery and Voltage Supply
Your winch draws a lot of current — if your battery is weak or wiring is undersized, the winch may fail to operate or stall under load.
- Use a multimeter to check voltage at the battery (should be 12.4V or higher).
- Check voltage at the winch terminals while pressing the control button. If it drops below 10V, you may have a battery, cable, or alternator issue.
- Confirm that your earth/ground cable is clean and tightly connected.
Step 3: Check the Remote Control
If pressing the remote does nothing, the issue could be as simple as a faulty controller or a dodgy plug.
- Try both wired and wireless controllers if available.
- Inspect the controller plug for corrosion or bent pins.
- Listen for a clicking sound from the solenoid/contactor when activating the remote.
Step 4: Bypass the Remote and Test the Contactor
This step helps you work out if the controller is the issue or if it’s the solenoid or motor.
- Locate your winch contactor (solenoid).
- With caution, use jumper leads to manually energise the winch motor directly from the battery terminals.
- If the motor runs, the contactor or remote is likely at fault.
- If it doesn’t, the issue is deeper — either in the motor or mechanical components.
Step 5: Test the Contactor Output
A contactor might click but still fail internally. Use a multimeter to see if it's passing power to the motor when activated.
- Place the multimeter on the output terminals of the contactor.
- Press the remote switch — you should see full battery voltage when the button is engaged.
- No voltage? Your contactor’s likely cooked.
Step 6: Test the Winch Motor
If you suspect the motor, a resistance test can give you some clues.
- Disconnect power from the winch.
- Use a multimeter to check for continuity between the motor housing (ground) and its terminals — there shouldn’t be any.
- Test resistance between the field terminals (e.g., F1 and F2). You should see a low resistance reading — not zero and not infinite.
Step 7: Rule Out a Mechanical Jam
Sometimes the electrics are fine, but the winch won't budge due to internal binding or external issues.
- Put the winch in free spool and pull out some rope or cable manually.
- Re-engage the clutch and try winching in.
- If the motor hums but the drum doesn’t turn, you may have a seized gearset or clutch issue.
Common Winch Issues and What They Mean
| Symptom | Possible Cause |
|---|---|
| No response at all | Faulty remote, flat battery, bad earth |
| Clicking but no motor movement | Weak battery, bad contactor |
| Motor runs but no drum movement | Disengaged clutch, jammed gearset |
| Only works in one direction | Faulty contactor or damaged switch |
Useful Resources
Final Tip: Always Troubleshoot Safely
Never troubleshoot your winch with a vehicle in gear, or with anyone near the cable or fairlead. If you're unsure, contact a qualified auto sparky or 4WD specialist.