80 series winch info

[drive it ...]

I've acquired an 80 series factory winch to stick in my Prado. Same as this pic.
http://forum.ih8mud.com/attachments/oem ... pg.199029/
A few comments on web about them locking up if you stall it under load. Anyone got any operator tips and or mods/fixes? (yep, I've got block for double pull)
Also mine is wound on same as that pic with the rope running off the top. I want it off the bottom to suit my fairlead. Can i just reverse the switch wires? Or are the solenoids set up for running a certain way (sorry if thats a dumb question, I really dont do electrics). I could mount it backwards and make a funky shaft for the freespool lever.

[mudlva]

Make a funky lever as the brake is set up for that rotation

[drive it ...]

Thks mud, I hadn't thought about the brake.

[mudlva]

Imho
remount the fairlead.
the front of the winch has a mounting to take shear load. This will become obsolete if winch is reversed.

Another idea is to create a vertical mount and then mount it so the base is under compression loading

[drive it ...]

Hmm. I initially thought the front bolt holes were just to hang the fairlead / bumper. But looking at parts diagram the factory front steel plate does wrap round and bolt to chassis rails. Which would resist the twisting force from it pulling off the top of the drum. So if I raise the lead it will be a whole re-engineer of my front bar to copy that. Which is out of my engineering skills range. On the other hand if I turn it round and pull off the bottom that's a lot less bending moment on the base bolts. And it has 8 base bolts vs 4 on my ex winch. So I'm leaning to the turn it around option.

Cheers again for the thought provoking comments.

[wjw]

They do stall and lock up under load, happened to me twice, only way to release was to attach another trucks winch to get some slack into the cable. was fine then. regarding mounting I turned mine round so the cable came off the bottom, as mudlva said its a brake issue...

Had it for about a year, got angry with it and bought a super winch.

[Jay]

I've had 2 factory toyota winches in the past... and both have had the issue of locking up under load and wont reverse, its a real pain in the A***. Once to the point where I had to VERY carefully tap the pin out of the hook end, while the cable was under strain... NOT FUN, but was left with no other choice.

Since then, I've got a 12,000 lb Runva... its never stalled on me, and reverse's everytime.

Jay

[Clint]

. and both have had the issue of locking up under load and wont reverse, its a real pain in the A***.

Yep, I've seen it happen with those winches too. It really is a huge PITA, even in a group. Remember, it's not going to fail somewhere nice, it will be 1/2 way up some greasy rutted hill you can hardly stand up on, in the rain, with the sun going down... Fitting one of those to your truck is like poking Murphy with a stick while shouting 'do your worst you little green bastard!'

Cheers
Clint

[wjw]

Fitting one of those to your truck is like poking Murphy with a stick while shouting 'do your worst you little green bastard!'

Needed something to cheer me up this morning... brillian!

[drive it ...]

Glad you're happy WJW. I was all excited about new toy , looks like I've got 40KG boat anchor.
I see service manual says to run ATF (I assume auto trans fluid) in the gearbox & clutch. You guys having lock ups didn't happen to be running normal gear oil or something? Grasping at straws here - trying to pretend my plan hasn't just come unstuck
And yep Clint - I can see the little green b***d waiting on that hill for me.

[mudlva]

They lock up under huge load.
listen to the winch and use a pully block when the winching gets real heavy.
theres thousands of them out there so a couple of complaints aint to bad all siad and done.
ive seen what they can do and will be running one on my new buggy obce shes up and wheeling.

Bolt it up and use it

[Mehrts]

Thinking out loud here..

If you carried a hi-lift jack, you could use that as a hand winch just to take the load off the electric one if it does decide to jam up on you. That should give you enough opportunity to get out of sh*t creek if it does happen.

[imsohi]

I run one on the comp truck as a back up I find them great. Only downfall is the brake locking on this happens only under extreme loads and to have it happen is 99% driver error not using there equipment correctly I have done it myself . If you learn to listen to the winch you won't run into any dramas and find that you are backing the winch off before it gets to the limit, then running a pull block. I have found also if it does lock up a good dose of throttle when backing the winch of works 50% of the time. They have prob one of the best out of the box free spools and it's easy to run a cable to it for in cab control. And Yea they run at fluid in the gearbox. Don't be put off by all the negative comments they are still a pretty good winch.

This is my 2c not trying to have a dig at anyone.

[Big]

I run one on the comp truck as a back up I find them great. Only downfall is the brake locking on this happens only under extreme loads and to have it happen is 99% driver error not using there equipment correctly I have done it myself . If you learn to listen to the winch you won't run into any dramas and find that you are backing the winch off before it gets to the limit, then running a pull block. I have found also if it does lock up a good dose of throttle when backing the winch of works 50% of the time. They have prob one of the best out of the box free spools and it's easy to run a cable to it for in cab control. And Yea they run at fluid in the gearbox. Don't be put off by all the negative comments they are still a pretty good winch.

This is my 2c not trying to have a dig at anyone.

Glad you piped up, as im looking at one myself..

[imsohi]

Yea I seen your offer lol good for when the mitsi packs up.

[drive it ...]

Good enough. Don't have a boat anyway. Back to plan.

Post by Mehrts » Thu Jul 02, 2015 9:47 am
Thinking out loud here..

If you carried a hi-lift jack, you could use that as a hand winch just to take the load off the electric one if it does decide to jam up on you. That should give you enough opportunity to get out of sh*t creek if it does happen.

Good thought, I'll look for a cable gripper clamp to hook the jack up with, like the power board crews use for pulling lines.

[wjw]

They lock up under huge load.
listen to the winch and use a pully block when the winching gets real heavy.
theres thousands of them out there so a couple of complaints aint to bad all siad and done.
ive seen what they can do and will be running one on my new buggy obce shes up and wheeling.

Bolt it up and use it

I used to go out on my own quite regularly with the 4 kids, not worth the risk to me.

[Jay]

Don't get me wrong, having A winch, is better than having none.... but for the price you can pick up a brand new one these days, I have to agree with wjw - Its just not worth the risk.

Maybe I just had a couple of dud's... but I can assure you, they weren't under huge loads... For a factory winch on an 2 tonne + bus like an 80 series, just didn't cut it for me.

Jay

[mudlva]

Humm. Ive seen one drag a vx right round waitawhata in 9 hrs and was pulling just about as hard at the end as it started in the morning.

Just thinking here that it could be an adjustment on the braking side that is binding them up?

[Clint]

Humm. Ive seen one drag a vx right round waitawhata in 9 hrs and was pulling just about as hard at the end as it started in the morning.

Just thinking here that it could be an adjustment on the braking side that is binding them up?

Could be lack of use makes them prone to lock up maybe? A really strong electrical feed may help in having the juice to over-run the brake?

The one I saw lock up was pulling a MWB 70 up a slippery hill, a reasonable pull but nothing crazy. The old 6000lb Warn on my my Suzuki would have done many harder winches than that.

Those cable gripper clamps or 'Kito Clips' are a great little item, anybody running a wire rope on their winch should have one.

Cheers
Clint

[drive it ...]

Found those kito grips at a rigging shop today. Over $300. Bloody good idea but... . Bought a few cable clamps and grabbed a short cable offcut from his bin so I can attach a loop sometime if need be.

[drive it ...]

Well if anyone wants to know, the 80 series winch does fit between KZJ prado rails. Only just though, maybe 15mm to spare. Its wee bit off centre, the fairlead in pic is centered.



I had previously cut away the panel below the grill. Have to put a bend in the radiator mount to clear the solenoid cover. Thinking of moving the solenoids up into engine bay a bit further away from the mud n water

Then the bad news. It was dripping a wee bit of oil (ATF) so I asked toyota what a seal kit was worth. "Dont have a kit, computer says end oil seal and one of the rings in the country, they'd be $135." Nah.

So pulled it down to get seals out to try and match. Hmm, been a bit of water in here before and the o rings are already not factory double lipped ones. All be ok with a clean up though. But worse to come, the flat on the motor end of the drive shaft has had a shock load and has a hairline crack - bugger! Suddenly this is not as much fun as I wanted.

Anyone point me at a good engineering firm in Chch that could build up and re machine a shaft?

[derk]

you want to take that old roller (and out of centre) fairlead off and mount a hause fairlead on there mate, the opening on the fairlead idealy wants to be narrower than the width of the winch drum to take the spooling/loading and cable bunching directly off the sides of the drum, the fairlead slot should be around 50mm+ narrower than the drum width

[Danjr]

you want to take that old roller (and out of centre) fairlead off and mount a hause fairlead on there mate, the opening on the fairlead idealy wants to be narrower than the width of the winch drum to take the spooling/loading and cable bunching directly off the sides of the drum, the fairlead slot should be around 50mm+ narrower than the drum width

Unfortunately I've learnt this the hard way - twice

The wire/rope spools off the side of the drum quite nicely and finds it's way perfectly into the slot between the drum and the winch at which point it proceeds to rip the rubber o-rings out of the drum as it splits your winch apart. Then trans oil pisses everywhere for the next few weeks. Should have been quicker to pick it up (listen to the winch) but definitely change that fairlead. I'm in the process of pulling mine to bits again to fix this but will sort the fairlead this time.

Not to hijack the thread but I've found mine difficult to move between freespool and into gear.

[Clint]

you want to take that old roller (and out of centre) fairlead off and mount a hause fairlead on there mate, the opening on the fairlead idealy wants to be narrower than the width of the winch drum to take the spooling/loading and cable bunching directly off the sides of the drum, the fairlead slot should be around 50mm+ narrower than the drum width

Top advice there.

Another (cheap) option is to keep your existing fairlead & just cut off the mounts for the vertical rollers & weld them back on further in. Make sure they're good welds.

$300 for a Kito clip doesn't sound right I got my one ages ago but I think it was like $30, looks like this:



Cheers
Clint

[DMcCready]

Bringing this thread back... other than the brake binding up what is the rest of the winch built like? Im most interested in the gear box and freespool.

[Big]

my understanding is the free spool is very good ( i have mine hooked up to a air ram though very low psi about 30 from memory) take out the 10mm bolt and it just operates.. gearbox's are filled with atf so again great idea for lube.. so like you brake is the only draw back so will post back any feedback when i get to use it in anger

[DMcCready]

Nice! I am looking at using one for a wee project but I havnt had the chance to have a good look over one myself