|Here's a pic of all the parts
you should get with your new
T-MAX EW-9500 winch. The yellow package is a T-shirt
|I picked up a Toys by Troy winch plate
to mount the T-MAX winch on and can say this thing is stout!!
|Using a 3/8" socket, remove the 2
bolts on each side of your Jeep attaching the front plastic cover
to your frame
|Using a Torx T-55 bit, remove the 2 bolts
on each side of your front bumper attaching it to the frame (or tow
hooks to it if you have them)
|Using an 18mm socket and wrench, attach
your roller fairlead to the winch plate using the bolts and nuts supplied
with the kit.
|Slide in the square nuts provided with
the kit into the slots at the located on base of the T-MAX winch
|Using a 16mm socket, Attach the T-MAX
winch to your winch plate. The bolts will thread into the square nuts
|Because I am still using a OEM front
bumper, I had to stack 3 washers on top of the swaybar bushing in
order to fill in the gap between it and the winch plate.
|Bolt the T-MAX winch and plate to your
bumper. The design of the Toys by Troy winch plate does not allow
you to use Mopar tow hooks so you will need to pickup a pair of aftermarket
ones or not install any
|This is a detailed photo of all the cables
coming out of your control box
|Using a flat head screwdriver, attach
your control box to the 2 mounting clips provided with the kit
|Place the 2 clips on top of the upper
winch tie-bars and then secure it by tightening lock screws
|This is a detailed photo of the terminal
bolts B, C, and D located on top of the T-MAX winch
|Using a 14mm socket, fasten the respective
cables to the appropriate terminals on your T-MAX winch
|This is what the cables should look like
once secure and with the protective boots on
|Slip both the thin ground wire from the
control box and one end of the negative batter cable to the Terminal
'A' bolt and fasten it to the bottom on the T-MAX winch
|Slip your battery cables through the grill
and run it along the fender as shown
|Using a 1/2" wrench, connect the
positive and then negative batter cable to your Optima Deep Cycle
|Here's what your new T-MAX winch will look like when all is
said and done
Features & Specifications
• 9500 lbs. rated single line pull
• 5.5hp Heavy Electric Reversible Motor
• 94ft. of 5/16” Galvanized aircraft cable with replaceable
• Motor: 5.5hp12V Series Wound: 6hp/24V Series Wound
• Control: Remote Switch - 12' lead
• Gear Train: 3-Stage Planetary
• Gear Ratio: 218:1
• Clutch: Sliding Ring Gear
• Brake: Automatic In-The-Drum
• EW-1100 Drum Size: Diameter 2.52" Lengths 8.82"
• Wire Rope: (28m) x 5/16" (8.2mm)
• Fairlead: 4-way roller fairlead
• Remote Control: Included
• Recommended Battery: 650 CCA minimum for winching
• Battery Leads: 2 gauge, 72"
• Finish: Black / Dark Gray
• Weight: 79Lbs
• Overall Dimensions: (L x W x H) 21.3" x 6.3" x 8.6"
• Mounting Bolt Pattern: 10.00 0.015IN x 4.50 0.010IN
EW-9500 Electric Winch
What Jeep is truly
complete without a winch. Beyond looking way cool, they are one of
the most functional pieces of recovery equipment you can own. The
problem, a good winch suitable for a Jeep can run anywhere from $400-$1000+
depending on the make and weight capacity. If that weren't enough,
you can't mount a winch to your Jeep unless you have a winch mounting
plate or a bumper that allows you to attach one to it and they can
run anywhere from about $50 (winch plate) to $500+ (new front bumper)!!
So, the question is, do you go with a name brand you can trust like
Warn and pay through the nose or, do you go with a cheap no name brand
unit like the kind you can buy at Harbor Freight?
What You Will Need
EW9500 Electric Winch
By Troy Winch Plate
• 3/8" Socket
• 1/2" Wrench
• 14mm, 15mm, 16mm, 18mm Socket & Wrenches
• Torx T-55 Torx Bit
• Ratchet Extension
• Torque Wrench
• Flathead Screwdriver (Medium & Small)
• Standard 10,000 lb. Tow Hooks if you currently have Mopar
• Optima Yellow Top or equivalent Deep Cycle Battery
• Zip Ties
As with any new mod, open your packages and verify that you have all
the pieces you need to do the install. There's nothing worse than
getting half way through and install only to find that you need something
you hadn't anticipated especially when your Jeep is the only ride
you got. In my case, I soon realized that my Mopar tow hooks would
not work with the Toys by Troy winch plate and so I went out to my
local 4Wheel Parts store to pick up a couple of standard 10,000 lb.
2. On to the installation. To begin, park on level
ground and then remove the plastic 'Jeep' cover located just behind
the front bumper using a 3/8" socket.
3. Using a Torx T-55 socket, remove the 4 bolts (2
on each side) on top of your bumper securing it to the frame. If you
have tow hooks, the bolts securing them are ones you need to remove.
4. Using an 18mm socket and wrench, attach your roller
fairlead to the winch plate using the bolts and nuts supplied with
the kit. Make sure that the bolt is slipped in from the back of the
mounting plate so that the threads are pointing out and the nut is
up front touching the fairlead.
5. Place your winch plate on a flat surface and set
your new T-MAX EW-9500 winch on top of it. Then, slip in the square
nuts provided with the winch into the slots as shown in the pic to
6. With the T-MAX winch still sitting flat on the mounting
plate, thread in the two rear bolts from underneath. You may need
to move the square nuts a bit to get the threads to catch. Tighten
these bolts down enough so that you can tilt both the T-MAX winch and mounting
plate without it falling apart.
7. Tilt the whole setup on its front face (sitting
on the roller fairlead) and then thread in the two front bolts. There
were no torque specs with this winch so I decided to torque all 4
bolts to 70 ft. lbs.
8. Carefully lift your new T-MAX winch and mounting
plate up onto your front bumper and check the fit. I found that my
Toys by Troy winch plate is designed with holes in it that allow you
to use the swaybar bushing bolts in addition to the bumper bolts.
Unfortunately, because I am still running an OEM bumper, I found there
was a small gap left between the mounting plate and swaybar bushing
that needed to be eliminated before bolting it all down. I found that
3 washers did the trick perfectly. If you have a winch plate that
can use these extra bolts, you will need a 15mm socket to remove your
swaybar bushing bolts.
9. Bolt the winch plate to the frame of your Jeep
using the factory bolts you removed earlier. If you have Mopar tow
hooks like I did, you will need to pickup a pair of standard 10,000
lb. aftermarket ones. The design of the Toys by Troy winch plate will
not allow you to reuse the Mopar square based ones. Or, you can always
just leave the hooks off altogether. Make sure to torque the 4 Torx
T-55 bolts down to 80 ft. lbs.
10. Take your T-MAX control box, lay it face down
and then attach the 2 mounting clips to the back of it with a flathead
screwdriver as shown in the pic to the left. Make sure that the hooked
side of the clips are facing forward.
11. Place the 2 clips on top of the upper winch tie-bars
(the clips hook on the front tie-bar and slides onto the back bar)
and then secure it by tightening lock screws as shown in the pic to
the left. Tightening the lock screws will require a small screwdriver
and a bit of effort.
12. Your new T-MAX winch has 4 electrical terminal
bolts, 3 of which are located on top and color coded. The fourth terminal
is the ground terminal and is located on the bottom side of the winch
housing. Connect the appropriate color coded cables to their respective
terminal bolts using a 14mm socket or wrench (There are 2 red cables
coming out of the control box. You need to attach the short one with
the protective boot. The longer one will need to be connected to your
battery) See pic to left for reference). Then attach both the thin
black ground cable and one end of the negative battery cable to the
ground bolt on the bottom of the winch housing (see pic to left).
13. Slip the protective weather boots over the terminal
14. Carefully route your positive and negative batter
lead through the grill of your Jeep and then up the side of your fender
as shown in the pic to your left. Secure them in place using zip-ties.
15. Secure your positive lead cable to your Optima
Yellow Top battery using a 1/2" wrench (NOTE:
make sure your negative lead is not touching anything metal) and then
attach your negative lead cable.
That should be it! Your new T-MAX EW-9500 electric winch and Toys
By Troy have now been installed!! Now it's time to test it out.
T-MAX EW-9500 Winch Operation
test out your new T-MAX winch, begin by finding an empty parking lot
with a bumper pole or other sturdy anchor point.
2. Park an adequate distance from the anchor point,
engage your parking brake, kill the engine, shift the clutch lever
on the winch housing to the "OUT" position and then pull
the winch cable out to the desired length.
3. Place a tow or tree-saver strap around the anchor
point, attach your winch cable to it (WARNING:
never wrap the cable around an object and hook it back on to itself.
This will case damage to the object and can kink or fray the cable)
and then re-engage the clutch to the "IN" position.
4. Check and the re-check all the cable rigging before
5. Remove the rubber plug from the face of the winch
control box and then plug in the remote hand control.
6. Make sure your Jeep is in neutral, start up your
engine and then release the parking brake. Stand clear to the driver
side of your Jeep and then switch the hand control to "IN"
and/or "OUT" until your Jeep has been retrieved. Check the
winch cable on a regular basis making sure that the cable is winding
onto the drum evenly.
7. When finished, remove and store your hand remote
control safely inside your Jeep.
Post Installation Notes
Well, so far so good. Installing the T-MAX EW-9500 winch and Toys
by Troy mounting plate was a piece of cake and a monkey with a wrench
could do it. Out of the box, I can tell you that I am very pleased
with the quality and construction of this winch. I will admit that
the only testing I have done with this winch to date has only been
a simple line out and Jeep retrieval test on flat pavement. This test
went as would be expected and the T-MAX EW-9500 worked flawlessly.
I will be sure to post an update as soon as I have the opportunity
to really test it out on the trails.
As far as
winch plates go, Toys By Troy makes one so beautiful and beefy that
it was almost a shame to cover it up with a winch. This is the very
first product I have purchased from them and I am very pleased with
their quality and attention to detail. Based on this purchase, I will
be buying products from them in the future.
Since installing my T-Max Winch, I've used it several times for light
duty work but this past weekend, I really put it to the test. While
wheeling in Anza Borrego, I ran into a few guys who managed to get
themselves seriously stuck in a alkali marsh. One was a full size
Ford and the other was a full size Chevy pick-up and both had completely
sunk their front ends into the muck. Fortunatly, the surface of the
marsh was still firm enough that if you could carfully navigate across
it but the first sign of tire spin and you're gonna dig in.
Parking my little Jeep TJ on the most solid ground I could find, I
proceeded to extract both vehicles using my T-Max EW-9500 winch. Make
no mistake, this was by no means an easy task. In fact, the Ford was
so severly stuck that at one point it acted as an anchor causing my
Jeep to be dragged towards it even though I was standing on the brakes.
Need I say, the T-Max never heistated, the motor never complained
and it performed flawlessly. The only problem I had was by the third
pull, my winch cable crossed over and got crimped. I guess I'm gonna
need to get me a new synthetic line :-)
Below are a few pics of the rescue.