Replacing Boat Winch Cable: A Step-By-Step Guide

Replacing a boat winch cable is a straightforward task that can save you money. Before you begin, ensure you have the necessary tools, such as a screwdriver, wrenches, and a new cable or strap. The process involves releasing the winch tube by detaching the winch cable and lift cables from the carriage, removing the pulleys, and carefully taking out the old cable. When installing the new cable, pay attention to the cable routing and make sure to test it a few times to ensure it's secure.

Tools required: screwdriver, curved pick, wrenches

To replace a boat winch cable, you will need a screwdriver, a curved pick, and a pair of 3/4" and 1-1/8" wrenches.

First, release the winch tube by detaching the winch cable from the winch and releasing the two lift cables from the carriage. The free end of the winch cable doubles back on itself and is held in place by a lead wedge within a slot. You can punch it out with a long screwdriver. This will also release the lift cable nuts.

Next, remove the winch tube and place it in a comfortable position to work on. Make a note of the cables, which pulley they lay in, and which side they exit the tube. Remove the pair of pulleys, which are secured by a 1-1/8" nut and bolt. Make sure to note which cable goes above and below the pulleys, as the winch cable goes around the lower pulley and exits the tube high, while the lift cable goes around the upper pulley and exits the tube low.

With the pulleys out of the way, you can now see the eye of the winch cable, which is held in place by a 3/4" bolt. Remove this bolt and use a hook to grab the eye end of the winch cable and pull it out. Now, you have both ends of the cable in your hands.

If you have the means to cut off the eye end, you can do so and then splice on a new cable. Otherwise, you can tie a fish wire to the free end and pull it through. Then, tie your new cable to the fish wire and pull it back around.

Finally, butt splice the free end of your new winch cable to the eye bolt end of your old cable. Make the splice strong, but thin enough to go around the snatch block inside the tube. You can use electrical tape around the splice and then cover it with shrink tubing for added security.

Now, gently feed your new cable through, ensuring that the lift cable is above the winch tube bolt and the winch cable is below it. Also, make sure that the cables are on the right side of the pulleys when you push them back in.

Removing the winch cable

Firstly, release the winch cable from the winch itself and also release the two lift cables from the carriage. This is how the winch cable is attached to the drum. The free end of the cable will likely be doubled back on itself and held in place by a lead wedge within a slot. You can punch this out with a long screwdriver or similar tool.

Now that the winch tube is off, make a note of the cables, which pulley they lay in, and which side they exit the tube. You will need to remove the pair of pulleys as they are in the way of the winch eye bolt. Make sure you take note of which cable goes above and below the pulleys, as this is important for reassembly. The winch cable goes around the lower pulley (but exits the tube high) and the lift cable goes around the upper pulley (but exits the tube low).

With the pulleys out of the way, you will be able to see the eye of the winch cable and the bolt that holds it in place. Make a note of which cable runs high and which runs low, as this will be important for reassembly. Now, release the bolt holding the eye in place. You can use a hook to grab the eye end of the winch cable and pull it out.

At this point, you should have both ends of the winch cable in your hands. If you don't have the means to cut off the eye end, you could tie a fish wire onto the free end and pull it through, before tying your new cable to the fish wire and pulling it back around. Alternatively, you could cut off the eye end and splice on a new cable, but this will require careful execution to ensure the splice is strong but thin enough to go around the interior snatch block.

Once you have removed the old winch cable, you can start the process of installing the new one. Remember to take your time and work carefully, ensuring that all connections are secure and that the cable is routed correctly through the pulleys and around the drum.

Attaching the new cable

• Prepare the New Cable: Before attaching the new cable, ensure that it is the correct length and type for your winch. You may need to cut it to size and attach a crimp fitting to the winch end. Make sure the crimp is tight and round so that it fits into the bevelled hole on the winch spool.
• Feed the Cable: Using the old cable as a guide, feed the new cable through the same path. Ensure that the cable goes around the pulleys in the correct orientation. The winch cable usually goes around the pulley low and exits the tube high, while the lift cable goes around the pulley high and exits the tube low.
• Secure the Cable: Once the new cable is fed through, secure it to the winch drum. This can be done by running a bolt through the holes in the side of the winch drum and the looped end of the cable. If your winch does not have holes, you may need to drill one to accommodate a bolt. Make sure the bolt is secure and will not come loose during operation.
• Test the Setup: After the new cable is attached, test the setup by launching your boat a few times. Ensure that the cable winds onto the winch spool correctly and does not become loose. Repeat this process a few times to make sure that the cable sets properly and can handle the load.
• Final Adjustments: Once you are satisfied with the performance of the new cable, make any necessary final adjustments. This may include greasing the pulleys, tightening any loose bolts, or adding additional wraps of the cable to the winch spool. Ensure that all components are secure and in the correct position before using your boat regularly.

Remember to exercise caution when working with winches and cables, as improper installation or use can lead to injury or damage. Always refer to the manufacturer's instructions and guidelines for your specific winch model.

Reassembling the winch

Now that you have both ends of the winch cable in your hands, you can proceed to the next steps. If you don't have the right tools to cut off the eye end, you can tie a fish wire to the free end and pull it through. Then, tie your new cable to the fish wire and pull it back around.

Alternatively, you can cut off the eye end and splice on your new cable. This way, you will only have to go around the interior snatch block once. Make sure to visualise this step before proceeding.

Now, butt splice the free end of your new winch cable to the eye bolt end of your old cable. Make the splice strong, but thin enough to go around the snatch block inside the tube. Cover both ends with electrical tape, then a piece of shrink tubing, and finally, a little more electrical tape.

If everything goes according to plan, you can now gently fish your new cable through. Once you're done, you can start reassembling everything. Make sure to run the lift cable above the winch tube bolt and the winch cable below it. Also, ensure that you get the cables on the right side of the pulleys once you push the pulleys back in.

It is recommended to clean both pulleys and lightly grease them with marine grease before reassembly.

Testing the new cable

Visual Inspection:

Start by visually inspecting the new cable for any signs of damage or defects. Ensure that the cable is not frayed, kinked, or damaged in any way. Look for any signs of corrosion or wear and tear. Check that the cable is properly routed through the sheaves and that there is no excessive slack or tension.

Functionality Test:

Once you have confirmed that the cable appears to be in good condition, it's time to test its functionality. Engage the winch and operate it through a complete cycle. Listen for any unusual noises, such as grinding or squeaking, which could indicate improper installation or cable damage. Ensure that the cable winds and unwinds smoothly and that there are no obstructions.

Load Test:

To ensure that the new cable can safely handle the intended load, perform a load test. Secure a load to the winch that is slightly heavier than the maximum expected load. This will ensure that the cable can handle typical loads without issue. Operate the winch to lift the load, paying close attention to how the cable performs. Ensure that the cable does not slip, bind, or become tangled during the lift.

Cable Tension:

After the load test, check the cable tension. Proper cable tension is critical for the safe operation of the winch. Adjust the tension according to the manufacturer's specifications. Incorrect tension can lead to premature wear, reduced winch performance, or even cable failure.

Final Inspection:

Once you have confirmed that the cable is functioning properly and has the correct tension, perform a final visual inspection. Check all components of the winch, including the cable, sheaves, and drum, for any signs of damage or abnormal wear. Ensure that all connections are secure and that there are no loose parts.

Remember, safety should always be the top priority when working with boat winches. Do not take any shortcuts, and if you have any doubts about the condition or installation of the cable, consult a professional or qualified technician.

Frequently asked questions