Winch Install Gone Bad - Lost All Power

[WarthogJr]

I'd just remove the battery from the vehicle and try the repair outside of the vehicle.

But yeah... sounds like the battery got shorted with no fuse to interrupt. Surprised you didn't hear anything honestly.

EDIT— Just for some added details: AGM batteries are considered to be fully discharged around 10.5 - 10.7 volts. When it's below that voltage it's considered "deeply discharged" and typically permanent damage occurs. And you said you were around 4 volts... so.... it's probably safe to assume the battery is dead or severely damaged. Hence why you want to keep it away from the Bronco.

Good advice. Maybe have a fire extinguisher handy also.

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[Saltwater Junkie]

Definitely remove the battery for bench testing. You have caused a dead short to the battery and it "maybe" savable. Some auto parts stores will have a true battery tester (I.e. MIDTRONICs) for loan, that MIDTRONICs type unit should/will stabilize the electrolytes to the point of taking some charge again.. after electrolyte stabilization, then test for a true CCA reading.
If the CCA's readings are well below what the battery info tag CCA is rated for,it's probably best to turn it in for a core refund.

 

[Bronco_MI]

I put a new Optima in. That's the only thing that was available at auto zone. All power came back on and the winch is working with the correct wiring. I'll take the original battery in and have it tested. Maybe I can use it on something else.

 

[Altitude]

I put a new Optima in. That's the only thing that was available at auto zone. All power came back on and the winch is working with the correct wiring. I'll take the original battery in and have it tested. Maybe I can use it on something else.

Glad it worked out. I'm sure it was scary there for a moment or two.

 

[swooshdave]

The diagram on the switch is to illustrate (perhaps poorly) that it's for a battery disconnect.

Regardless the instructions appear to be pretty clear to me. Especially the warning that if you don't know what you are doing, you shouldn't do it.

 

[TX-Dennis]

Hey. We learn by making mistakes. At least this one only cost you $250 or so for a new battery.
It could have been a lot worse including a trip to the ER.

 

[GroovyGeek]

Battery must have internal current limiters if this thing did not spark or catch fire. I would not reuse that switch or any of the provided wiring. At minimum inspect them carefully for degraded insulation, signs of overheating, etc

 

[telenerd]

Forum saves the day! Thanks everyone for coming together.

 

[BadlandsA51]

Battery must have internal current limiters if this thing did not spark or catch fire. I would not reuse that switch or any of the provided wiring. At minimum inspect them carefully for degraded insulation, signs of overheating, etc

There’s a chance the switch acted like a fuse and shut the circuit down. I wouldn’t rely on the switch at this point. Luckily the battery didn’t blow up, I’ve seen that happen, it’s not pretty!

 

[Twister22]

I threw that switch away and used a keyed switch in my front bumper. The bumper already had holes in it for the sensors which I didn’t have so I used one of the holes to put the switch in.

 

[dgorsett]

Looking at the switch, I only see 2 terminals there, but you say you wired (+) and (-) to it.

the switch is just to interrupt the (+) - there shouldn’t be any (-) at all to that switch.

(+) from battery to switch. From switch to (+) on winch control box. (-) on winch to chassis or battery ground. That switch does not have a solenoid operator, it’s just a manual disconnect (the diagram @HoosierDaddy posted would be for a relay type connection with a remote cutoff). Place the switch as close to the battery as you can conveniently mount it.

so.. how exactly did you connect the wires and … did your battery jump, explode or pop when you flipped the switch.

If you direct short the battery without a fuse it’s fairly dramatic

This

 

[Broncobadlands2023]

The diagram on the switch is to illustrate (perhaps poorly) that it's for a battery disconnect.

Regardless the instructions appear to be pretty clear to me. Especially the warning that if you don't know what you are doing, you shouldn't do it.

Lol that’s pretty clear that you shouldn’t dead short your battery to the switch

sorry OP, have to laugh. Thankfully you’re okay and didn’t cause any damage to yourself or property.

edit: I lied, I see that switch, wtf is that!! I’d send that to HF, that’s confusing AF.

 

[swooshdave]

Lol that’s pretty clear that you shouldn’t dead short your battery to the switch

sorry OP, have to laugh. Thankfully you’re okay and didn’t cause any damage to yourself or property.

edit: I lied, I see that switch, wtf is that!! I’d send that to HF, that’s confusing AF.

It's not that confusing. It's a drawing of a battery not a schematic on the switch.

It's an expensive test to see if you should be working with electricity or not...

 

[vrtical]

It's not that confusing. It's a drawing of a battery not a schematic on the switch.

It's an expensive test to see if you should be working with electricity or not...

On a good note, it reminded me I needed to buy a Stinger relay as I am getting ready to finally install my winch. I got two of my higher amp up fitters that I wont be using for any roof lights so gonna utilize one of them.

 

[BrentC]

Although, these AGM's are pretty damn stout... the one thing Ford did get right was the battery.

Interesting comment, only because I had my battery replaced on warranty last year. My Bronco was a 12/21 delivery.

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