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Be careful as you route these remaining wires through the engine
compartment. Keep them clear of the area near the exhaust manifold as this
can easily melt the insulation and cause problems. Likewise, keep your
wiring clear of moving components (belts, pulleys, throttle linkages, and fan
blades). Do not route your wires in such a manner that causes tight bends
on sharp surfaces (sheet metal and such). Using the after market wire
protectors is a good idea and provides an extra measure of protection for your
I slipped open the factory cable protector to expose three of the four wires that will be connected to the red, white, and black wires in the short white TWC cable. We used the supplied splice connectors and attached the wires according to the TWC install directions. Nothing difficult here unless you are color blind!
With the wires spliced together, electrical tape was applied and everything was wrapped with a couple layers of tape. The servo cable was then rerouted to its previous position and the speed control servo was attached to the bracket.
The remaining white TWC cable will be connected to the winch. The install directions show a typical connection for a Warn winch. I would recommend that you verify your winch connections match those in the directions. This can easily be done with an ohm meter. Connect one ohmmeter lead to the Warn winch hand controller connector. You will be using the ground, winch in, and winch out pins as shown in the directions. Connect the other ohmmeter lead to the top of the solenoids as shown in the directions. You should show 0 ohms between the appropriate connector pin and its corresponding solenoid terminal. My Warn 9000i matched the diagram in the TWC install directions. Make sure yours does too.
To remove the cover on the Warn 9000i, remove both top bolts (one on each side) from the side of the side of the winch. You may need to loosen the other two bolts (on just one side) so that the cover can be removed. If you don't have a Warn winch with the integrated solenoids, you will have to determine how to open the solenoid box and proceed with that Winch model. Again, I'll mention that you are just connecting three winch control wires, ground, winch in, and winch out. If you have a wiring diagram for your winch, you should be able to extract the applicable information from it.
Here is a peak of what the 9000i looks like with its lid removed. Be careful when you are finished and go to replace the cover.....you don't want to pinch any of the existing or new control wires under the lip of the cover.
Since we had just removed the cover, Mike suggested that now would be a good time to drill a hole in the cover. He mentioned that I didn't want to get the crimp on connectors on the end of the cable and THEN realize that we hadn't routed the cable through the cover. Good point! We used a 1/4" drill bit and then inserted the plastic grommet into the hole. The cable was then routed through the hole and cut to an appropriate length.
NOTE: I will confess here that I didn't catch the sentence in the TWC install directions that said to drill the hole in the side of the winch's solenoid compartment. IMO, it makes no difference once you are done.
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