How to Install Synthetic Rope on WARN Winch? – [Step by Step Guide]

As a leading manufacturer of vehicle winches, WARN industries has a decades-long commitment to quality. Whether you’re looking for truck winches, SUV winches, or Jeep winches, WARN has always set the bar high for what you need to get started. Off-road winches range in pulling capacities between 8,000 lb and 16,500 lb, so our focus with WARN winches is variety.

Installing synthetic rope on WARN winch

The likelihood that your winch line will deliver the best performance is non-existent without successfully installing a synthetic rope on it. The winch needs to be installed properly to provide the rope with long-lasting capabilities to resist external wreckages (and internal ones) and maintain its effectiveness. Just get into the decision of learning the exemplary processes it involves. Let’s take a closer look at the intricate process of installing a synthetic rope on a WARN winch. Read this article all the way to the end.    

install Synthetic Rope on WARN Winch – Guide

There are many kinds of winch models, each designed to handle a different kind of work load. It is therefore crucial that you identify the correct model of the WARN winch so that you can identify the type of job it has to perform before you can install synthetic rope. Imagine if incapable winches had even the slightest chance of performing heavy tasks? No, the job is doomed from the start. You can now master the DIY of installing synthetic rope on your WARN winch by reading through the steps listed below.

Step 1: Inspection of the winch

Start by disconnecting any electrical connections before inspecting the winch. The fairhead mechanism and steel cable that guide the rope should be removed. You should search the drum for any sharp or pointed objects. Sharp things have the potential to damage and rip the ropes. In addition to the steel cable, the drum can also be damaged. Thus, inspect thoroughly. If you come across any sharp objects, use sandpaper or another appropriate equipment to smoothen the drum.

Step 2: Installation of Fairlead

Installing the fairlead is required before you tie the rope. To avoid damage to the synthetic winch lines, they must be worked smoothly. For better protection, aluminium hawse fairleads are recommended. The cast steel ones have a rough feel to them and cause cable damage. In most cases, you can also use steel rollers since they facilitate a smoother transition and eliminate sharp objects.

If you are installing fairleads, it is important that the rollers overlap each other. If the rollers do not overlap each other (as with the old fairleads rollers), that would be very convenient. In that situation, there may be a gap in the corner, and the cables may become stuck, tearing or damaging the cable!

Maintaining proper clearances is another important factor. There should be ample space between the fairlead apertures and the mounting plate end. An ideal clearance should be 3/8-inch to 1/2-inch. The winch can be destroyed if the clearance is not maintained properly.

Step 3: Let the rope slide

If the synthetic rope has abrasion, you should check it. An abrasion sleeve is usually included with synthetic ones. The sleeve should be affixed to the cable’s endpoint. Next, roll the rope around the drum beginning at the bottom and threading the rope through the fairlead. To do this, you’ll need to grab the rope and partially pull it over the winch drum.

Hold the wires with pins or pliers once you’ve halfway pulled the ropes through the hole. It is now necessary to do two tasks simultaneously. Begin wrapping the wire while simultaneously pulling the rope from the hole. The rope must be passed through the hole or pocket. This makes it easier for the rope puck to stay in the midst of the roll. Removing the wire will allow you to mount the rope puck. The winch rope/cable is secured to the drum using the rope puck anchor.

Taking the string off the drum is easy. It’d also remove the puck from the drum. Make sure the puck remains in the loop at all times. Without any difficulty, the puck settles into the drum. Once the puck is properly placed on the drum, the eyelet won’t move, and everything will hold tightly to the surface.

Step 4: Make sure the wires are taut

As soon as you have completed the preceding steps, connect the negative connections of the winch to the electrical connections. If the clutch lever is engaged, it must be in this position. Ensure it is in the engaged position if it isn’t already. Roll the wires around in the drum now.

Make a slight tension with the wires to determine if everything is working properly. If everything goes well, spool the rest of the wires with a bit greater force than the first. Unroll and lay the cable roll in the ground first, then roll up the whole roll. Then try recoiling the drum. We’ve simplified and made this process more efficient.

After you’ve finished, try pulling in and pulling out the cables a few times. The winch cable will work fine or not based on the outcome of this test. You should rewrap the winch rope properly after each use after unwrapping the entire line.


So from what you have learned till now, one thing you are absolutely sure about installing a synthetic rope on WARN winch, isn’t a simple task. That is precisely why, you found this guide compartmented into small parts with every detail clearly etched out. It was a genuine attempt from our side to clear every possible doubt in a simple way so that you never have difficulties, installing a synthetic rope on WARN winch. Nevertheless, you are free to share with us any query you might have while following the procedures.

This is where we conclude as he have now finished the guide on how to install synthetic rope on a WARN winch.

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