Suspension winch cable repair

IamNoob

New Member
Joined
Sep 15, 2025
Location
Roxboro, NC
The cable broke on my rear suspension winch, about 8" from the loop. I need to cut the cable off evenly and put a new loop in it. Crimping it would probably be the best way to repair it. If you don't have a way to crimp it, what's the best solution? How is everyone repairing these?
 
Cable clamps if you don't have a hydraulic crimper and thimbles. Depending on how much room you have, I'd put two clamps, should be enough for the small winch, unless you went all out and have a bigger winch. Cutting the cable is key to doing a clean job. I have had good results using my welder to cut the cable. Turn it up on high and burn the bad part off. This will melt the cable end and keep it from fraying. Make the loop as tight as the cable will allow, then put one clamp close to the loop. The next cable clamps a couple of inches from the first. Take the cable and pull some slack on the tail of the cable and put the second clamp on, leaving a small loop between the two clamps. Not necessary., but, if the clamps allow the cable to slide any, just a look at the repair will tell you that. (the cable slips, and the slack straightens out) I also wrap some electric tape around the burned in and the feed cable, just in case it frays, this way it doesn't create a razor blade.
 
Personally, For a suck down winch, I'd just replace the Wire Cable with a Synthetic Rope, If you need it quick, you can find ATV winch ropes at Harbor Freight and Tractor Supply on the shelf, But if you have time, there are tons to choose from on Amazon under $30, Some under $20.

Then when it does break again, Repair options on synthetic line are much easier, and free, until the rope gets too short to tie properly...
 
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