12,000 lb Hydraulic Winch Installation |
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Front view of radiator after removal of grill, fenders, and bumper118 views
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Left side (looking forward) of radiator after grill and bumpers removed.101 viewsTape measure is shown for illustration of dimensions only.
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Top view of "Uncle Ray" discrete winch tray, after painting.105 viewsNote that towards the upper right there is a notch in the tray. This is needed for the specific winch's electric solenoid. The winch is a Mile Marker 12,000 lb hydraulic unit.
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106 views"Uncle Ray" discrete winch tray, back and rear views. After painting.
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Hidden winch mount with winch in place123 viewsHydraulic hoses are now installed. Note notch for hydraulic:electric solenoid to fit in mount.
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Front bumper view of semi-installed winch119 viewsNote the left-side (looking forward) bracket holding the white windscreen washer bottle.
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Installed winch with hydraulic hoses177 viewsThe hydraulic hoses are stiff, so I had to run them up the side of the radiator (can just see inside red boxes) to near the top of the radiator, then back down inside the engine compartment, then underneath the engine (behind the radiator) to the D4's power steering rack, where the hoses become metal. This hose routing may not be possible if the fuel-burning heater is in place (we don't have those in Aust and the space allowed room for my hands to bend and run the hoses without kinking).
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Close-up front view of partially-installed winch120 viewsNote that the sheet-metal flange just above the winch had to be notched to allow winch controller to be actuated. Also this same bracket had to be bent upwards to allow the winch hydraulic:electic solenoid to fit without rubbing. The nut on the upper-left bolt (the one with a very faint circle around it) stripped on re-installation, so the tray and winch pulling load is held only by the threads on 7 bolts....
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Front-right view (looking forward) of partially installed winch and mount124 viewsThe closest bracket, with three rubber grommets, is the air bag sensor. Before beginning any of this work, be sure to disconnect battery and discharge any remaining electrical power. I didn't want to accidently drop this assembly and cause the airbags to deploy.
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Front bumper with cutout for winch rope entry117 viewsBumper was initially cut "too small" with a low speed hand-held jig saw. It was then progressively filed to about the right size. Finally a very sharp box cutter was used to provide a smooth edge to the cut. This cutout is hidden behind the licence plate.
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Installed winch with electrical solenoid connections162 viewsI routed the electrical supply (2 small wires) up the side of the radiator. You can see the unconnected wires inside the red boxes. I ended up connecting them on the radiator diagonal strut with cable ties. They are out of the way for any deep water transits there.
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Installed winch, with bumper partially re-installed203 viewsPutting the D4 back together. Shows the tools and owner lying about.
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Installed winch electrical wires147 viewsWires which only power the solenoid are inside spiral wrap. They are also connected inside the wrap at the high point of the loop. Cable tied into place to prevent vibration rubbing.
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View of both hose connections to power steering system152 viewsBoth connections are shown. My friendly Qantas hydraulic hose expert cut off the elbow and modified it so I can re-install it to the PS rack before warranty work (and certainly before the vehicle is lifted off the body!!).
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Further detail of attachment of the winch hoses to power steering system144 viewsThis is under the right (looking forward) lower plastic radiator cover.
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Detail of hydraulic hoses attached to power steering hoses154 viewsHoses are attached to the upstream side of power steering rack. When winch not running, PS rack sees full pressure (ie, no change from design). Biggest challenge is running stiff hoses so that they align with attach points. I got Qantas employee who repairs hydraulic baggage loaders to braise in fittings (very tight spaces and tough access).
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Winch as installed177 viewsLicence plate is held on by winch cable and 4 metal pins which fit into modified bumper body. Winch rope is green
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