How to Change a Winch Rope
Changing the rope on your winch may be done for a number or reasons, including rope damage, switching to a larger size rope, or maybe switching to a synthetic rope. The process is not difficult and can be done easily in a hour or two at home in the driveway with common hand tools. If you are changing diameter of the rope, be sure to check the rating on the rope itself. If it is too light, you may break the rope when you really need it.
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Instructions
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Removing the Old Rope
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1
Set the clutch on the winch to freewheel and pull the old winch rope completely off the drum. You will find a small bolt in the drum holding the end of the rope to the drum when you get all the rope off.
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2
Remove the retaining bolt from the drum, and pull the rope out through the fairlead of the winch. Don't lose the bolt, you will be reusing it.
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3
Clean any rust, corrosion or other material off the drum so it does not end up under the new rope and damage it. Small sticks or even a nick in the drum could fray the rope when wound onto the drum.
Spooling the New Rope
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4
Lay out the new rope as straight as you can. If you are running a long rope, this may mean running it down the sidewalk or edge of the road.
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5
Slide the new rope into the fairlead with the eyelet or loop for the retaining bolt in first. Be sure to run the rope in so that it spools off the bottom of the drum when you are pulling with it.
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6
Apply some thread locking compound to the bolt and slide it through the eyelet or loop. Thread it into the drum and tighten with a socket and ratchet or open end wrench.
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7
Wind the first layer of rope onto the drum by hand, making sure that the rope is tight and the winds lay tightly together. This is important because if the base layer isn't right, the rope will become tangled and could be damaged.
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8
Spool the rest of the rope onto the drum by winding the winch while maintaining slight pressure on the line. It should almost wind itself, but watch it closely to be sure the layers are tight and laying down smoothly and evenly.
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Tips & Warnings
Sometimes it is easier to attach the winch rope to a stationary object and, with your vehicle in neutral, winch in. This will maintain the constant slight pressure on the line as it spools in.
Be careful working around the winch. Getting a hand or clothing item into the moving drum could cause serious injury.
