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Old 11-07-2015, 05:44 PM
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Used Warn xd9000i Question

Picked up a used warn xd9000i yesterday for $300. The paint looks like hell but it's mechanically sound with no rust except some surface rust on the drum. It has a new motor and solenoids, so for the price, I'll overlook a few cans of primer and rattle can paint. But my question is about the steel cable end. It doesn't have a thimble on the inside of the cable, just a loop of cable (it can be seen in the picture below). From what I've read, it should have a thimble to prevent damage to the line. If I am incorrect in this assumption, please let me know. But if I do in fact need a thimble, how to I go about inserting one? Could I place a thimble in the existing loop and use a clamp to keep it in place? Or do I need to cut the line and set up a new termination? Doesn't matter to me how it gets done, I just want it done it right.
Also, swapping in a new cable is very low on the list of things I'd prefer to do right now. I plan on switching to synthetic cable eventually, but if it can be avoided with a simpler fix in the time being, my wallet would greatly appreciate it.



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Old 11-07-2015, 10:00 PM   #2
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This what it looks like stock. I have the same winch.


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Old 11-07-2015, 10:07 PM   #3
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I think I remember seeing a forum discussion somewhere debating if those "cable guards" are actually nessisary. With how big that current loop is in your cable though, I wouldn't chance it. I would just put a new loop in the end with the "thimble" to be safe.
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Old 11-07-2015, 10:07 PM
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Sccafire - Exactly. Most winches I've seen have that style of cable termination. Posted this on another forum as well and one guy said his cable is like mine…but that doesn't mean it's correct.
But my question is, is the thimble (the little teardrop shaped piece of metal on the inside of the loop) absolutely necessary to avoid kinking the winch line? And if so, how do I set that up? Or will I be ok without it?
Thanks for the pic btw! I couldn't find a way to attach an example of what I was talking about.
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Old 11-07-2015, 10:11 PM
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I think I remember seeing a forum discussion somewhere debating if those "cable guards" are actually nessisary. With how big that current loop is in your cable though, I wouldn't chance it. I would just put a new loop in the end with the "thimble" to be safe.
So you're saying cut the current loop clean off and start fresh with a new loop. Do you know how to do that? Setting up that little sleeve isn't as easy as it seems, and I need a tool to crush the sleeve around the cable.
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Old 11-07-2015, 10:16 PM   #6
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I went to Factor 55 website. They show that metal thimble piece you are talking about. Looks like you are going to need one for the cable. Personally I would wait for synthetic. Synthetic does not require that metal piece.
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Old 11-07-2015, 11:14 PM
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I went to Factor 55 website. They show that metal thimble piece you are talking about. Looks like you are going to need one for the cable. Personally I would wait for synthetic. Synthetic does not require that metal piece.
Only problem is, now that I've got the winch, I don't want to just wait for synthetic line before I can use it…but I guess that day will come sooner rather than later. Unless someone else comes along with the solution.
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Old 11-08-2015, 10:17 AM   #8
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Call Warn. They will gladly help you out.
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Old 11-08-2015, 10:27 AM
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Call Warn. They will gladly help you out.
Good point. I was already planning to call them to see about some replacement stickers to make it look all pretty after some paint anyways.
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Old 11-08-2015, 12:24 PM   #10
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Only problem is, now that I've got the winch, I don't want to just wait for synthetic line before I can use it…but I guess that day will come sooner rather than later. Unless someone else comes along with the solution.
I totally understand you not wanting to wait to install the winch. Synthetic rope are not that expensive. Well at least to me. Check out some websites.

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Old 11-08-2015, 02:16 PM
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I've checked most of them. And I agree they aren't that expensive. For the most part, they're pretty much what I paid for the winch.
I know I want a rope made of Dyneema (spelling?) so viking, master pull, winch line.com, etc.

By chance does anyone know what the ropes at 4lowparts are made of? They have the safety thimble that I want (the one designed by Mr. Blaine) and pretty fair prices on the ropes even when not on sale.
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Old 11-08-2015, 04:05 PM   #12
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A thimble and two good rope clamps will work just fine but the clamps probably won't go through your fair-lead, so it will have to hang out a bit. Put the thimble in the loop and put the first clamp on loose and drive it toward the thimble to tighten the loop. tighten it down and install the other one. Just remember to put the saddle on the pulling side of the cable and the u-bolt over the tail. Cut off the remaining tail. You can cut the tail will a torch and kinda melt the end like you would on a piece of nylon string to stop fraying.
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Old 11-08-2015, 05:27 PM
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A thimble and two good rope clamps will work just fine but the clamps probably won't go through your fair-lead, so it will have to hang out a bit. Put the thimble in the loop and put the first clamp on loose and drive it toward the thimble to tighten the loop. tighten it down and install the other one. Just remember to put the saddle on the pulling side of the cable and the u-bolt over the tail. Cut off the remaining tail. You can cut the tail will a torch and kinda melt the end like you would on a piece of nylon string to stop fraying.
"Never saddle a dead horse". I've considered that, but biggest problem is that I don't have a torch. My other problem is that it reduces line strength to 80%. And because I don't know, and can't know, how the line has been treated, there's no telling what that 80% is now. I'd rather be safe and not hurt someone or myself than have $300 in my pocket. So I guess you could say I'm 50/50 on the synthetic line at this point.

Here's my reference for that 80% stat. I found similar numbers across the web when researching this myself before posting. It's also a very good source of info in general Pirate4x4.Com - Extreme Four Wheel Drive
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Old 11-09-2015, 01:09 PM   #14
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The existing loop has lots of extra room in it. How about just putting a smaller thimble in the loop you have, leaving the existing compression sleeve, and then add a single clamp to take up the slack? That should safely and inexpensively give you a functional winch connection until you're ready to upgrade to synthetic rope. The likelihood that you'll be putting even 80% of the full rating of that cable onto the winch is pretty slim, unless you plan to hang your Jeep over a cliff or out of a tree.
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Old 11-10-2015, 02:34 PM   #15
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Great information. I work in the mining industry and we do a lot lifting and pulling of very heavy equipment and machinery so I've seen my fair share of cable failures. As for using cable clamps they work, but have their limits. One thing you can do is braid an eye in the cable and then put clamps on, the cable most always fails before the clamps slip. I will say it would be hard to braid an eye as small as you need, but you might want to look up how it's done.
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Old 11-10-2015, 06:29 PM
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Great information. I work in the mining industry and we do a lot lifting and pulling of very heavy equipment and machinery so I've seen my fair share of cable failures. As for using cable clamps they work, but have their limits. One thing you can do is braid an eye in the cable and then put clamps on, the cable most always fails before the clamps slip. I will say it would be hard to braid an eye as small as you need, but you might want to look up how it's done.
I did look up how to do the flemish eye and I agree it would be very hard to make a loop small enough with just my tools at my house. But after looking through lots and lots of threads and weighing my options, I'm just gonna go ahead with synthetic line. 4lowparts has some great line and it's a very good price from what I've seen elsewhere.
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Old 11-10-2015, 06:51 PM   #17
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That's a great winch! Congrats on the score.
I luckily found my old used XD9000i shortly after my new Chinawinch failed.
I couldn't believe how much better it performed than my previous winch in all aspects.
The paint was chipping on the solenoid cover. I did a crummy job covering the bare spots with some rattlecan gunmetal Rustoleum.
My cable eye didn't have anything but a hook in it. Looked like yours, see the dumpster pic.
I used it this way for years before I also went with a 4lowparts synthetic.



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Old 11-11-2015, 01:17 AM
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Our winches just have character
I've heard nothing but great things about 4lowparts and I love the thimble on the end of the line. The more I looked at it, the more I realized what a fantastic design it really is.

I'm guessing you went with 100' of line?
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Old 11-11-2015, 08:24 AM   #19
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3/8" x 85'
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Old 11-11-2015, 01:53 PM
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3/8" x 85'
That's what I'm going with at first. Slightly less cost prohibitive. And it's only 15'
Do you keep any extensions with you? If so how long? Just curious
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Old 11-11-2015, 02:54 PM   #21
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That's what I'm going with at first. Slightly less cost prohibitive. And it's only 15'
Do you keep any extensions with you? If so how long? Just curious
Not an actual winch line extension. I have not needed one...yet!
I carry a 6' tree saver, 20' and 30' tow straps, as well as a Superyanker kinetic recovery strap.
I will be ordering some of those nifty new soft shackles.
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Old 11-11-2015, 03:04 PM
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Not an actual winch line extension. I have not needed one...yet!
I carry a 6' tree saver, 20' and 30' tow straps, as well as a Superyanker kinetic recovery strap.
I will be ordering some of those nifty new soft shackles.
Those shackles looked awesome! I've got a recovery strap and some crosby shackles. Just need to get a tree saver and thinking about a snatch block.

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