Warn Winch - Control Box clicking but not winching

You can replace the solenoid with jumper leads to see if that is the problem. One way is at the end of this article:
https://www.4x4australia.com.au/gear/recovery/1606/how-to-service-a-4x4-winch

I had a similar problem with my Runva winch - the solenoid was stuffed. It clicked but the winch didn't spool in (out was ok - so the solenoid was only half stuffed!)

Az, Most likely to be the solenoids, it can be costly to replace them all, you can try the winch with the engine running to give it move voltage, or connect the aux battery if you have one, if this works then consider how many times you'll get stuck and not be able to run the engine, against buying solenoids.This works for me, I have used my warn many times on heavy loads,I always use a pulley, If it's still no good ring Warn, the're very helpful. Regards Keith

make sure you have battery voltage at the solenoid
an or a bad or lose battery cable connection
cheers mechpete

I have had a similar problem with my WARN 12000.

Try removing all the power leads and giving the terminal and the terminal posts a good clean before reattaching. Make sure you do the battery end as well.

Run the vehicle whilst using the winch.

Hopefully will solve your problem. A lot cheaper and easier than checking and replacing solenoids.

Cheers

Anthony

I had a similar problem and it turned out to be that the motor had seized due to rust, the winch will let water in but not allow it to drain out. So I dismantled the motor and cleaned up the rusty inside, then I added a drain hole. ARB compressors have the same issue, sealed well enough to stop water draining out but not well enough to stop it getting in!
Gazza

Top End Az,
My winch, same model, had the same symptoms. Removed winch, pulled it apart to find 2 of the brushes in the motor had jammed in the holders. Freed them up and all working ok again. I had used it in anger, and it had been submerged in mud and water a lot of times.
If it is the problem, it is an easy fix with some CRC.
Your best idea --
I realise now I should probably use it a few times a year just to keep it all working properly.

By the way I just removed my winch from the bullbar this morning. I use a couple of ropes to lower it to the ground. There are only 4 main bolts holding it, disconnect the control box another 2 screws and disconnect the power supply. Remove the hook from the wire so it slips through the fairleads.

Good Luck,

Yep another for stuck brushes from mud and rust. Clean up and lubricate them and it'll be fine.

unless you aid top dollar for the waterproof version Warn winches nor their control boxes are waterproof.

Pretty much any winch even the ones that claim to be waterproof should be serviced if they get immersed.

If you are mechanicaly tallented it's pretty straight forward ..... dismantle clean & regrease.

As I understand The warn control boxes are not realy state of the art ...... pretty much the whole box or the guts thereof can be replaced with one of the more modern single block sealed solenoids from one of the generic winch suppliers or from ebay/amazon.

they pretty much all wire the same.

cheers

An update for future reference; I had a good look over the winch on the weekend. First checks where to check the fuse, all battery connections, terminals and battery charge which all checked out ok.
With the help of my mechanic neighbour we then used a test light to check that power was getting to the terminals on the winch body which is was, so the conclusion being all the solenoids, electrical connections and so forth were fine.
So, this being the case, it was time to remove the winch from the Dmax which meant accessing it from the bullbar. Contrary to what I first thought of needing to remove the whole bullbar, the ARB bullbar has 3 bash plates underneath, by which once removed (takes 10 minutes) enables sufficient room to unbolt the winch from the front (after removing the rollers), disconnecting the battery and all the connections from the winch body. It comes straight out with plenty of room to spare.
Opening the winch up was a bit of an ordeal but once opened we could see that the brushes were corroded, and the actuator was a bit rusty on the bottom, no doubt from sitting in undrained water. After cleaning up these and giving it a spray we reinstalled it, tested it and now all good to go.
All up it took about 3 hours to do all this, and I have no mechanical inclinations whatsoever, so I encourage anyone whom has a problem with their winch to give it a go. I reckon it's still a 2 person job to help with the winch removal and putting it back in purely from a perspective of making it easier to line up the bolts etc. Anyway, long story short, thanks to all for helping me with some troubleshooting tips and advice.
If only Warn made their winches waterproof, considering the nature of a winch which you'd expect to be used in an offroad environment. If there is anyway to waterproof it I'd be interested to hear it, otherwise I think from now on I will be sticking a tarp across the front to try and limit water from entering the winch area next time I go through any decent water crossings.