i have a warn xd 9000lb winch on my 1997 xj. the winch is throwing sparks when i try to extend it or retract it. the sparks are coming from where the cable rubs the rollers to guide the cable. i have checked the power and ground wires, and they seem to look good.
i was wondering if anyone has had this problem or has any advice in how to get this fixed?
thanks jeremiah

 

They SEEM to look good, or they ARE good? If sparks are coming from anywhere on the winch, unhook all power from it, and retrace your steps. Did you just hook the winch up, or has it been installed for awhile and is just now sparking?

 

Check your ground lead from the battery. There may be a bad connection and it is trying to make the ground through the cable and rollers.

 

X2

 

ok so i cleaned the connection for the ground and the power at the battery. those are looking good. the ground that runs from my battery bolts to the outside front of the winch. then on the back side of the winch there are 3 more black wires that run into the control box, I'm assuming those are grounds wires as well. the connections on the winch appear to be clean and looking good as well. i thinking of checking the ground for my battery and making sure that its good. i'm also thinking it could be a problem in the control box with the connection for the solenoid's. kinda scared to work on them tho, considering the posts are rusty and the last time i did this one of the posts broke, and had to replace the solenoid yesterday.
so im going to pull off the whole winch tomorrow considering its inside my bumper, so i can try and find the problem.
anyone have any other ideas before i go taking it all off?
any ideas to get those rusty nuts off and back on with out breaking a post?

thanks for you help guys.

 

oh and hurley842002, i bought my jeep with the winch installed, and was working fine, till one day it decided not to work at all......when i was in 4 feet of Colorado snow. that was a pain to dig out so i could get pulled out.