Hummer H1 (2006+). Manual — part 407

13-2

Accessories

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Winch Troubleshooting

Winch Inoperative

1.

Check for a jammed winch cable.

2.

Check the winch control cable connector for corrosion or a loose connection. Clean the corroded connector or secure the loose
connection.

3.

Check for a loose or damaged winch power cables. Using a voltmeter, connect the positive meter lead to the positive power
cable (red) at the winch motor, and the negative meter lead to the winch motor ground cables (black). If the voltage is not
present, repair or replace the winch power cables.

4.

Disconnect the winch control from the winch. Using an ohmmeter, check for continuity between the common terminal and the
other two terminals on winch control cable connector. Check for continuity one at a time, while holding the control in the OUT
position and the IN position. If continuity is present in both positions, repair the winch. If continuity is not present in both
positions, replace the winch control.

Winch Replacement

Removal

WARNING: To avoid personal injury or damage, support winch during removal.

1.

Disconnect the battery ground cables (Section 12).

2.

Remove the two battery cable bolts, battery cables, and the winch cables from the battery (Figure 13-1).

Figure 13-1: Winch Cables On Battery

3.

Remove the nut, lockwasher, capscrew, and the clamp from the right frame extension. Discard the lockwasher. Pull the winch
cables through the splash shield to the front of the vehicle (Figure 13-2).

POSITIVE WINCH

BATTERY

NEGATIVE

POSITIVE

BATTERY CABLE

BATTERY

CABLE

CABLE

NEGATIVE

WINCH CABLE

BATTERY CABLE

BOLTS

6-1-05

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Accessories 13-3

5745804

Figure 13-2: Frame Bracket

4.

Remove the four nuts, washers, bolts, and the winch from the front bumper13-3.

Figure 13-3: Winch and Winch Cables

5.

Remove the two bolts and the clamps securing the winch cables to the winch.

6.

Remove the bolt and the control box cover from the winch.

7.

Remove the capscrew, washer, and the negative winch cable from the winch.

8.

Remove the bolt and the positive winch cable from the winch.

Installation

1.

Install the positive winch cable on the winch with the bolt13-3.

2.

Install the negative winch cable on the winch with the washer and the capscrew.

3.

Coat the motor end of the winch with coating compound.

4.

Install the control box cover on the winch with the bolt.

5.

Secure the two winch cables to the winch with the two clamps and the bolts.

6.

Install the winch on the front bumper with the four washers, bolts, and the nuts. Tighten the bolts to 60 lb-ft (81 N•m).

FRAME BRACKET

POWER CABLES

CLAMP

CLAMP

POSITIVE

CONTROL

NEGATIVE

FRONT BUMPER

WINCH

BOX

COVER

WINCH

CABLE

WINCH

CABLE

6-1-05

13-4

Accessories

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7.

Route the winch power cables through the splash shield.

8.

Install the winch cables on the frame bracket with the clamp, capscrew, lockwasher, and the nut (Figure 13-2).

9.

Connect the battery ground cables (Section 12).

Winch Cable Replacement

WARNING: To avoid injury, wear gloves when handling the winch cable.

Removal

1.

Remove the cotter key from the clevis pin and discard. Seperate the clevis pin from the hook and remove the hook from the
winch cable.

2.

Unwind the winch cable.

3.

Remove the set screw and winch cable from the drum assembly (Figure 13-4).

Figure 13-4: Winch Cable

Installation

1.

Install the hook and clevis assembly on the winch cable

2.

Attach the winch cable to the drum and secure with the set screw.

CAUTION: Install the winch cable on the drum under a load of at least 500 lb (227 kg), or the outer wraps will draw into
the inner wraps and damage cable.

NOTE: Spool the winch cable according to the rotation label on the winch or the brake will not function.

3.

Rewind and lubricate the winch cable.

Winch Assembly Repair

Disassembly

1.

Remove the winch and the winch cable.

NOTE: Tag the leads for assembly.

2.

Remove the three nuts and the control leads from the motor
(Figure 13-5).

SET SCREW

CABLE ANCHOR

WINCH

HOOK

CLEVIS

PIN

COTTER

KEY

CABLE

6-S13-003

6-1-05

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Accessories 13-5

5745804

Figure 13-5: Control Leads

3.

Loosen the clamps and remove the control from the motor (Figure 13-6).

Figure 13-6: Control Unit

4.

Remove the clamps from the motor.

5.

Mark the motor end drum support, gear train assembly, and the gear end drum support for assembly (Figure 13-7).

00-S13-005

LEAD

CONTROL

DRUM SUPPORT

NUT

MOTOR

00-S13-006

CONTROL

CLAMP

MOTOR

6-1-05