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Wire Cable Replacement Instructions

Internal Halyard Winch System Diagram
  1. Raise the flag and cut the cable to be replaced above the swivel.
  2. Remove the tape from the top end of the replacement cable.
  3. Splice the top end of the replacement cable to the cut end of the cable to be replaced. The splice should be strong and its diameter should be equal to or smaller than the cable diameter. A splice we recommend involves tying five wires from the center strand of the old and replacement cable together. This can be done by peeling back and cutting the six outer strands about four inches from the end of the old and replacement cable. Unravel five wires from the exposed center strand of the old and replacement cable and tie them together. Cut unused frayed cable and tape the entire splice including the cut outer strands. The result should be a strong but small splice. Test splice before proceeding.
  4. Gently feed the new cable in through until the replacement cable, splice, on the outside of the truck appears. Continue feeding splice and replacement cable into the access door until the new swivel reaches the truck. At this point, the splice should be at or below the handhole.
  5. Cut the replacement cable just above the splice. Add the ball, two crimps, yoke, and swivel (optional). Adjust height of yoke to be at or just above handhole, before securing crimps. Remove the old cable from the winch and secure the new cable to the winch by placing the stop sleeve into the slot on the winch drum and tightening the screw against it securely.
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