Via Warn – One regularly asked question we often get in customer service and at shows is—when do you need to replace your winch line? This is a great question. The answer varies, but here we’ll give you some guidance for both steel and synthetic rope.
Inspect Your Rope
Steel rope and synthetic winch lines have pros and cons, but both need to be regularly inspected. Each can also have its own unique sets of issues due to the differing construction.
To inspect your line, place the winch’s clutch into the freespool position and pull the rope out down to the anchor. First, check to see if the anchor is in good shape and is securely attached to the drum. If not, resecure or replace it with a new one. Different winches and ropes have different kinds of anchors, but replace it with whatever it originally had.
Next, inspect the entire length of your line for frayed strands, cuts/slices, or kinks (steel rope). If your rope has any of these symptoms, it should be replaced. Never used a rope that has these issues, as it can cause a dangerous winch line failure. Additionally, if your synthetic rope has become shaggy with lots of little frays (sort of like it needs a haircut), it’s time for a new rope.
Note: Synthetic rope can occasionally become flattened under pressure when rope layers build up. Usually, a flattened rope isn’t necessarily compromised and will come back to shape under tension. Pay close attention to whether the strands themselves are frayed, however.
Inspect The Fairlead
While you’re inspecting your rope, also look at your fairlead. The fairlead helps guide your line onto your winch drum. There are two kinds, roller and hawse. Roller fairleads are self-explanatory. They have four rollers—two on the top, two on the side—and are for use with WARN winches with steel rope. If your rollers are broken, it’s time for a new fairlead.
Conversely, hawse fairleads don’t have rollers, and instead use an opening with a large, smooth radius for the rope to pass over. Our aluminum hawse fairleads (including our Epic Fairleads), are for synthetic rope. Warn does offer a cast iron hawse fairlead for those who want to use it with synthetic rope, and a few of our applications, such as PullzAll, utilize steel line and a hawse.
If you’re using synthetic rope, ensure the hawse fairlead is still smooth and free of nicks. Any abrasion on the fairlead can damage the rope. Remember: abrasion is the top enemy of synthetic line. While synthetic rope is very strong, it’s easy to damage. Wire rope, on the other hand, is exceptionally resilient to abrasion, but is heavier, harder to work with, and stores more kinetic energy. When it comes to steel vs synthetic rope, the choice is yours.
Steel Rope Replacement
If you’re in need of a new steel line, Warn offers replacement steel rope in a variety of lengths and diameters for your winch, whether that’s a truck, powersports, or industrial unit. Warn recommends using the same diameter and length of rope the winch came with. This is because the rope was designed and tested to be used with that winch.
Since steel rope is so durable, there isn’t a whole lot to worry about when replacing it; it’s a straightforward process:
1. Put the winch in freespool.
2. Unspool the steel rope until you get to the rope’s anchor.
3. Remove the anchor, and the rope.
4. With the old steel rope off the drum, take the new rope, feed the end through the fairlead, and attach it to the drum using the specified anchor point.
5. Reinstall your hook or winch line shackle mount to the end of the new rope.
6. Wind the new winch line onto the drum in the correct orientation. You’ll want to stretch the rope before use and now is a good time to do so. Please see our video on How To Stretch Rope for more information.
Synthetic Rope Replacement
Replacing your winch’s synthetic rope is nearly the same as steel. However, due to synthetic rope’s sensitivity to abrasion, we recommend inspecting the winch’s drum for any knicks, scrapes, or high spots that could cause damage. If present, use sandpaper to smooth down such areas.
Again, Warn recommends replacing your synthetic rope with the same size line as it came with from the factory. However, if you have a truck winch, you can upgrade to WARN Spydura Nightline, the company’s high-visibility rope. It’s available in 80’ and 100’ lengths, both of which are 3/8” diameter. Spydura Nightline’s red, black, and reflective weave is as strong as our standard Spydura, but is excellent in low light, and can easily be seen.
WARN Spydura Nightline features a reflective weave, for high visability in low light conditions.
Some WARN winches in capacities of 12,000 lbs. (5443kg) or more come with WARN Spydura Pro synthetic rope. This is a heavier-duty line designed for the higher capacities. Just ensure you install the correct rope when it comes time to replace it.
The steps for replacing synthetic rope are nearly the same as steel rope:
1. Put the winch in freespool.
2. Unspool the rope until you get to the rope’s anchor.
3. Remove the anchor, and the rope.
4. Inspect the winch drum for burrs, nicks, or other spots of abrasion. If present, remove them with sandpaper.
5. Inspect the fairlead for burrs, nicks, or other spots of abrasion. If present, replace the fairlead.
6. With the old synthetic rope off the drum, take the new rope, feed the end through the fairlead, and attach it to the drum using the specified anchor point.
7. Wind the new rope to the drum. Stretch the rope before use. Again, see our video on How To Stretch Rope for more information.
Can I Change from Steel Rope to Synthetic Rope?
Synthetic rope has become very popular in the vehicle recovery world, and many users would like to make the switch from steel to synthetic rope. In most cases, you can switch from steel to synthetic line.
If you opt for the switch, make sure your steel rope hasn’t scored, knicked, or created any sharp areas on the drum. This can happen with steel rope as it bites into the winch drum under load. If these sharper areas are present, sand them down with sandpaper.
Additionally, we recommend removing your old roller fairlead and switching to a smooth, large-radius hawse fairlead. Warn Industries’ hawse fairleads and Factor 55 fairleads are intended for use with synthetic rope.
Again, after any rope replacement, be sure to stretch your line before use.
WARN and Factor 55 offer a wide range of premium hawse fairleads, designed to reduce wear and extend the life of your synthetic rope.
Steel or Synthetic: When In Doubt, Swap It Out
The bottom line: Always replace compromised rope, whether it’s steel or synthetic. Never use a compromised rope line. Always inspect your rope before heading out on an adventure. If you think it is compromised, get a new one. It’s a safety thing.
If you happen to break your synthetic rope on the trail, it can be mended using a Factor 55 Fast Fid. However, a sliced line (not a broken one) should always be replaced. It’s simply a matter of safety. And yes, you can go from steel to synthetic rope but just be sure to follow best practices when doing so.
Quick and easy on-the-trail fixes are possible with the Factor 55 Fast Fid, rope repair kit.
