I have a XD 9000 winch which is wired with an in cab controller as well as a removable 5 pin remote. I extended the 5 pin receptacle of the solenoid box about 14 inches to allow me to mount the Solenoid box inside my bumper so that only the the receptacle is mounted outside the bumper. The in-cab remote wiring was spliced into this extension.

My XD 9000 pooped out last week when I was attempting to extracate myself out of a slippery situation at Tillamook. As I got tension on the winch rope, the winch ceased to work. I assumed it was because of faulty in-cab remote wiring so I busted out the 5 pin plug in remote and plugged it into the receptacle. Needless to say I got the same outcome, a clicking of the solenoids, but no forward or reverse motion from the winch. I tried to activate the winch all day that day with nothing but clicking solenoids. I assumed that my problem was caused by too much:beer: meaning too many splices and too small a wire(16gauge).

So today I decided to rewire using 12 gauge wire, but before I did that, I decided to see if the winch would work when I didnt need it. "Wallah!" it worked, but I figured that a no load situation may well be easy enough for the wiring to handle, thus the miraculous recovery. Regardless I spent 4 hours rewiring the entire connection between the in-cab remote and the 5pin remote receptactle with 12 gauge wire. I reduced the number of splices from 6 to 2 and felt confident this would do the trick. After this was completed I grab the 5 pin remote and proceeded to try to push some line out. BUT, Click, Click. Nothing. I then put it into free spool to try to loosen something, actually I just did it out of frustration and started cussing at the rope as I yanked it out at a steady pace. After this display of stupidity, I proceeded to PULL the Line IN via the remote and "Presto" it fed the line perfectly. I dont know if the gears were binding or what? Hoping you guys may know whats going on here.

I then pushed some line out so that I could pull my rig in to see how the winch performed under load. It worked like a charm except for on one occasion. I was pulling in my rig and spooling it evenly at the same time, and when I got I MISwrap I quickly reversed the rope direction. When I did this the winch stopped again, and went back to clicking its solenoids. Out of frustration, I just kept pushing forward and reverse frantically, and all of the sudden the winch worked again. Am I doing something wrong or is this usual for the winch or this particular winch to be so tempermental? I proceed to repeat the winching under load 2 more times and the winch performed flawlessly both times even when I was erratically going from forward to reverses. The only thing I can think of is a bad solenoid. If so, how do I know which one needs to be replaced?

Mine is doing the exact same thing. Mine will click 50 times before it will work, then when it works I dont let off until im done cuz if I do it will just click again for A while. Im so tired of it oh and it just gets worse and worse. Hope somebody has fixed this prob. and if it is one bad silinoid, how do you find out which one it is.

Not sure about the 9000i, but on my 8000 the motor grounds through the housing. Mine did this once and tightening the mounting bolts and tightening the bolts that hold the motor on to give it a better connection fixed it. Also make sure you have a good ground from the battery to the frame

Which Gurus, where are you. The XD 9000 uses a ground from the solenoid which is connected to the winch motor ground, which in turn is connected to the battery ground.

If its a bad ground, would the Solenoid still click?

You more than likely have a bad solonoid, I'm not sure how to tell which one, give Warn a call, they're pretty knowledgable. I did however go ahead and replace all 4 of them, it cost me about 40 bucks. They were all original, might as well start fresh.

Originally posted by StoutOne


If its a bad ground, would the Solenoid still click?

Yes, it could.

You could have a good connection and read voltage throughout the entire system. But as soon as you put a load on it, the ground may not be enough. However, it sounds more like a bad solenoid to me. It is common for them to work intermittently when they go bad. You can test this by using an Amp meter but a voltage reader will most likely give you false readings.;)

Bad solenoid ALL DAY LONG...

I would agree with bad solenoid. Also make sure the nuts on the solenoids are tight, don't tighten too much though. (easy to break the solenoid)