Winch Autostop Kit

P/N 2889690

1 Before You Begin

Read these instructions and check to be sure all parts and tools are accounted for. Please retain these installation instructions for future reference and parts ordering information.

IMPORTANT
This Autostop Winch Kit is intended for use with HD 4500 Lb. Winch Kit (PN 2889695).

3 Required Sold Separately

Only parts for installation of the are included. Prior installation of the following additional kits are also required (sold separately):

  • HD 4500 Lb. Winch Kit, P/N 2889695

If the rope on the winch is damaged/needs replacement, the following additional kit is optional (sold separately):

  • Synthetic Winch Rope Kit, P/N 2879187

4 Kit Contents

Ref

Qty

Part Description

P/N Available Separately
1 1 Controller, Winch n/a
2 1 Fairlead 2637781
3 1 Bracket, Mount 5271082
4 1 Stop Magnet, Bumper 5415787
5 1 Bumper, Jounce 5418451
6 2 Screw, Torx, Pan Head, Self Threading, 10 x 5/8 in 7518238
7 2 Screw, Socket Head, (M10 x 1.5 x 30 mm) 7519844

5 Harness Detail

Autostop Controller 1

Ref

Part Description

Connects to
2F Fairlead connector Fairlead
4F Contactor connector Contactor
4M Main wire harness connector Main wire harness

Example: 16F = 16 pin, Female / 16M = 16 pin, Male (Male terminal fits inside female terminal)

6 Tools Required

  • Safety Goggles

  • Pliers, Side Cutting

  • Pliers, Slip Joint

  • Screwdriver, Slotted

  • Screwdriver Set, Torx®

  • Socket Set, Hex Bit, Metric

  • Socket Set, Metric

  • Torque Wrench

  • Wrench Set, Metric

7 Important

Your is exclusively designed for your vehicle. Please read the installation instructions thoroughly before beginning. Installation is easier if the vehicle is clean and free of debris. For your safety, and to ensure a satisfactory installation, perform all installation steps correctly in the sequence shown.

8 Installation Instructions

8.1 Vehicle Preparation

8.1.1 General

  1. Park vehicle on a flat surface.

  2. Shift vehicle into PARK.

  3. Turn key to OFF position and remove key.

8.1.2 Battery Disconnection

NOTICE
Battery is located under passenger seat for ranger 3 seat 1000. Battery is located under back passenger seat for crew for ranger crew 1000.
WARNING

Ensure red positive (+) battery terminal is COMPLETELY COVERED by protective boot. Accidental tool contact across both battery terminals will result in high current electrical arc, and may result in battery explosion. Death or serious injury may occur.

  1. Lift up passenger seat.

  2. Remove bin and set aside.

  3. Loosen nut on negative wire and remove wire from battery.

8.1.3 Grille Removal

  1. Push two tabs down to remove grille.

8.2 Accessory Installation

Replace Standard Fairlead with Autostop Fairlead 2

  1. Remove and keep clevis pin and cotter pin from hook. Remove and keep hook.

  2. Remove and discard two fairlead screws. Remove and discard fairlead and backer plate.

  3. Install autostop fairlead 2 using two new screws 7 and fairlead backer plate 3. Route fairlead wire through the opening. Torque screws to specification.

    IMPORTANT
    Do not pinch wire. When tightening screws make sure that the wire is not pinched or strained.
    TORQUE

    Screws 7:

    40 ft-lbs (54 N·m)

Bumper Removal
CAUTION
Bumper weighs approximately 31 lbs lbs (14 kg). Failure to adequately support bumper during removal may result in personal injury or damage to equipment.

  1. Remove and keep nut A and bolt B. Repeat for opposite side.

    NOTICE
    Right side detail shown; Left side similar.

  2. Support bumper, remove and keep nut C and bolt D. Repeat for opposite side.

    NOTICE
    Right side detail shown; Left side similar.

  3. Set aside bumper on a sturdy surface.

Autostop Controller 1 Installation

  1. Remove and keep two lower screws and nuts.

  2. Remove and keep two upper screws.

  3. Tilt up winch frame from the bottom. While tilted, install autostop controller 1 with two screws 6. Torque until full seated.

  4. Reinstall two retained lower screws and nuts. Torque to specification.

    TORQUE

    Nuts:

    40 ft-lbs (54 N·m)

  5. Reinstall two retained upper screws. Torque to specification.

    TORQUE

    Screws:

    40 ft-lbs (54 N·m)

  6. Disconnect contactor A from the main wire harness. Connect 4F contactor connector to contactor A

    .
    NOTICE
    Winch part hidden for visibility

  7. Connect 4M harness connector to vehicle harness B.

    NOTICE
    Winch part hidden for visibility

  8. If rope is in need of replacement, install Synthetic Winch Rope Kit, PN 2879187 (sold separately).

Bumper Installation and fairlead connection
CAUTION
Bumper weighs approximately 31 lbs lbs (14 kg). Failure to adequately support bumper during installation may result in personal injury or damage to equipment.

  1. Support bumper, install nut C and bolt D. Torque to specification. Repeat for opposite side.

    NOTICE
    Right side shown; Left side similar.
    TORQUE

    Nut C:

    36 ft-lbs (50 N·m)

  2. Install nut A and bolt B. Torque to specification. Repeat for opposite side.

    NOTICE
    Right side shown; Left side similar.
    TORQUE

    Nut A:

    36 ft-lbs (50 N·m)

  3. Connect 2F fairlead connector to fairlead wire C.

Install Bumper Jounce and Hook.

  1. Thread loop through the fairlead, bumper jounce 5 and stop magnet 4. Reinstall retained hook, cotter and clevis pin at end of loop.

    IMPORTANT
    Make sure that the rope is straight from the winch spool to the fairlead without touching the winch tie bars.

8.3 Vehicle Reassembly

8.3.1 Grille Installation

  1. Put bottom of grille in first and push top of grille in until two tabs engage upper front fascia.

8.3.2 Battery Connection

NOTICE
CREW VEHICLES: connect battery under right rear passenger seat bottom
WARNING

Ensure red positive (+) battery terminal is COMPLETELY COVERED by protective boot. Accidental tool contact across both battery terminals will result in high current electrical arc, and may result in battery explosion. Death or serious personal injury may occur.

  1. Connect wire to battery and tighten nut.

  2. Install retained bin seat.

  3. Close seat.

9 Operation

OPERATIONAL CHECK

IMPORTANT

The Autostop system is intended to prevent winch damage caused by over-tightening the rope, but cannot prevent all possible winch damage. The winch system is very powerful and care should be exercised whenever it is in operation.

The winch operator is always responsible for using the winch properly, as described in the “Winch User Guide” included in the winch kit. The Autostop system should only be used as a secondary preventive measure to help prevent damage to the winch from over-tightening the rope.

NOTE
During rope recovery the winch should automatically stop when the magnetic stop 4 comes close to or contacts the autostop fairlead 3 (within approximately 1 inch (25 mm)). Magnets in the stop trigger sensors in the fairlead, stopping the winch.

10 Instruction Feedback Form

A feedback form has been created for the installer to provide any comments, questions or concerns about the installation instructions. The form is viewable on mobile devices by scanning the QR Code® or by clicking HERE if viewing on a PC.