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I couldn't quite get the nut driver into the proper position so
I loosened a couple of the heavy battery connections to make some room.
You can see the black (ground), white (winch out), and red (winch in) wires
connected to the appropriate solenoid terminals on my 9000i.
While I realize that the Warn winch cover is not water tight, we decided to put a couple dabs of silicone sealer on around the cable penetration. We also put a cable tie on the inside and outside so that the cable could not be pulled or pushed through the cover. The winch cover was carefully put back into position (make sure you don't pinch any wires) and the bolts replaced. Make sure to tighten any bolts that were previously loosened.
You have one remaining wire, that long yellow one, from the TWC box that must be connected to the camshaft position sensor. I noticed that there was no picture for a 6 cylinder TJ with a distributor in the install directions. No biggie...the one for 4 cylinder was close enough for me. (OK, I'll confess again and mention that I checked my ''98 FSM just to make sure I was splicing the correct wire.)
The remaining splice connector is used to attach the yellow TWC wire to the tan/yellow wire coming out of the distributor housing. Once again, I used electrical tape to wrap everything up and provide some protection. Be careful as you route the yellow wire through the engine compartment. The comments I made earlier apply equally well to this wire too.
Mike had to leave just after we finished with the winch connections so he wasn't there for the final checkout. I am happy to report that everything worked just like the operations section of the owner's manual stated. I started the vehicle and first tried the throttle control. It was too cool to see the engine RPMs ramp up and down as I played with the right hand group of cruise control buttons. With that out of the way, I had my wife try the other group of switches. Sure enough, the winch powered in and out, just like it was suppose to.
I put my tools away and cleaned up the plethora of zip tie snipits and called it complete! Just to make sure all was well, I took it for a drive and made sure the factory cruise control still functioned as it had. No problem there....it worked just fine.
Total install time was about 7 hours. We took our time taking pictures and discussing wire routing paths. When ever Mike and I get together, there will always be some off topic discussions which does nothing to further the progress of our wrenching project.....which was demonstrated on multiple occasions during this install. But hey, I already said I really enjoy Saturdays and especially those when I get a chance to spend it with Mike. Before I forget, thanks Mike for all the help. I look forward to the next time.
In summary, I am very pleased with the TWC from Kwan Motorsystems. I had a chance, before receiving the TWC, to exchange e-mail with them and they were most helpful in answering my questions. Although I've had no "problems" (and I don't expect too), I will say that the customer support I've received to date (pre-sale) was second to none. I look forward to trying it out on the trail.
Update October 07,2003
After posting this write-up on the JeepsUnlimited forum, one of the members inquired about the type of interface it has with the Warn winch. It seems that Warn has an issue with one of the aftermarket wireless winch controllers that is made by another company. I contacted Kwan Motorsystems and they were nice enough to send me the following information concerning the TWC.
Most Warn winches (the older ones do not) have a redundant switch arrangement. I don't know how the radio/wireless remote is designed, but the TWC has the same redundant hook up similar to the Warn remote, however it uses MOSFETs.
I've included a picture of the similarities between the Warn remote and the TWC. The 5 control wires are labeled 1, 2, 3, 4, 6 (total 5 wires) in reference to the pictured connector (winch connector face not the remote connector).
|When reeling in:||
Warn Remote: S1 and S3 are closed
TWC: Q1 and Q3 are activated.
|When reeling out:||
Warn Remote: S2 and S3 are closed
TWC: Q2 and Q3 are activated.
Since the Warn remote is portable, pins 3 and 6 on the Winch Connector supplies the +12V and GND. The TWC receives its +12V and GND through the DPST switch that was in the kit. In the diagram it's left out but is noted as 12V and Chassis (GND). The DPST switch in the kit is on purpose. While the TWC will still function with the BLK wire connected directly to chassis, it's main purpose is to add an additional safety precaution in case the TWC fails for some reason. It's mainly for the throttle side of the TWC.