Wire Cable Replacement Instructions

Replacing the stainless steel wire cable on an internal halyard winch flagpole is a straightforward procedure when you splice the new cable to the old one and feed it through the truck. This guide walks you through each step — from cutting the existing cable to securing the new one on the winch drum.

Prepare the Replacement Cable

Before splicing, the top end of the replacement cable needs to be exposed and ready to bond with the old cable.

1. Unwrap the End

• Remove the Tape: Carefully remove any factory tape from the top end of the replacement cable.
• Inspect the Cable: Check the strands for fraying or damage and trim back any loose wires before continuing.

A clean, well-prepared cable end is critical for forming a strong, low-profile splice.

Splice the Cables

The splice is what allows you to pull the new cable up through the flagpole using the existing cable as a leader. The goal is a connection that's compact, strong, and able to pass smoothly through the truck.

1. Prepare the Cables

• Trim the Outer Strands: Cut back the six outer strands of both the old and replacement cables about four inches from their ends.
• Expose the Center Strand: This leaves the center strand of each cable exposed for splicing.

2. Create the Splice

• Unravel the Center: Unravel five wires from the center strand of each cable.
• Tie the Wires: Tie the unraveled wires from each cable together to form the splice.
• Match the Diameter: Ensure the splice is strong and that its diameter is equal to or smaller than the original cable diameter so it can pass through the truck.

3. Secure the Splice

• Trim & Tape: Cut off any frayed cable and tape the splice and the cut outer strands securely. The splice should be compact and robust.
• Test for Strength: Test the splice for strength before proceeding to ensure it won't separate while feeding it through the flagpole.

A solid splice prevents the cable from separating mid-pull, which is by far the most common cause of failed cable replacements.

Feed the New Cable

With the splice complete, you'll use the old cable to pull the new cable up through the flagpole, around the truck, and back down to the access door.

1. Pull the Splice Through the Truck

• Feed Gently: Gently feed the replacement cable through until the splice appears outside the truck.
• Watch for Snags: Pull steadily and stop immediately if you feel resistance, since forcing a stuck splice can break it.

2. Route Through the Access Door

• Continue Feeding: Continue feeding the splice and cable into the access door until the new swivel reaches the truck.
• Position the Splice: Ensure that the splice is at or below the handhole so you can cut it off in the next step.

Once the new cable is routed correctly and the swivel is seated, you're ready to remove the splice and complete the installation.

Finalize the Installation

The final step removes the splice, attaches the flag arrangement hardware, and secures the cable to the winch drum so the flagpole is ready to operate.

1. Remove the Splice

• Cut the Cable: Cut the replacement cable just above the splice so only the new, unspliced cable remains.

2. Attach the Hardware

• Install Components: Attach the ball, two crimps, yoke, and swivel (if applicable).
• Position the Yoke: Adjust the yoke so it is at or just above the handhole before securing the crimps.

3. Secure the Cable on the Winch

• Remove the Old Cable: Remove the old cable from the winch.
• Seat the Stop Sleeve: Secure the new cable by placing the stop sleeve into the slot on the winch drum and tightening the screw against it firmly.

With the new cable seated on the winch drum, run the flag arrangement up and down once to confirm smooth operation before putting the flagpole back into regular service.