When tackling deep water crossings, your winch is your lifeline. But here’s the problem—most winches aren’t truly waterproof. Water, mud, and grit can seep into the motor, corrode electrical connections, and leave you stranded when you need it most.
The good news? Waterproofing your winch is easier than you think. In this guide, I’ll walk you through a step-by-step process to make your winch water-resistant and ready for extreme conditions.
How Waterproof Are Winches from the Factory?
Most winches claim to be “water-resistant,” but that doesn’t mean they’re fully waterproof. Winches come with IP ratings (Ingress Protection) that indicate their level of protection against dust and water.
- IP67-rated winches can handle temporary submersion in water up to one meter.
- IP68-rated winches offer better protection, handling continuous submersion at specific depths.
But here’s the catch—factory seals degrade over time, and even IP68 winches can still take on water. The motor housing, solenoid box, and electrical connections are all weak points.
If water gets in, rust can form, gears can seize up, and electrical components can short out. That’s why DIY waterproofing is a must.
Tools & Materials Needed for DIY Winch Waterproofing
Before diving in, gather these essentials:
✔ Waterproof grease – Dielectric grease for electrical connections and marine grease for moving parts.
✔ RTV silicone sealant – Seals gaps in motor housing and solenoid box.
✔ Heat shrink tubing – Protects electrical wiring from moisture.
✔ Electrical tape – Adds another layer of insulation.
✔ Synthetic winch rope (optional) – Unlike steel cable, synthetic rope doesn’t trap water or rust.
✔ Drain hole modification (optional) – Helps water escape instead of pooling inside.
With these materials in hand, let’s get to work.
Step-by-Step Guide to Waterproofing a Winch
A winch is a vital recovery tool when off-roading, but it’s not immune to water damage. While some winches come with water-resistant seals, they are not truly waterproof. That means prolonged exposure to water, mud, or even just heavy rain can lead to rust, electrical shorts, and mechanical failure.
Waterproofing your winch is a DIY-friendly process that involves sealing vulnerable areas, reinforcing electrical connections, and using water-resistant lubricants. Below, I’ll break down each step so you can properly protect your winch for deep water crossings.
Step 1: Disassemble and Inspect the Winch
Before making your winch waterproof, you need to open it up and inspect the internals. This will help you identify existing weak points where water might seep in.
How to Disassemble Your Winch:
- Remove the winch from the mounting plate. Most winches are secured to a bumper or winch plate with four bolts. Use a socket wrench to loosen and remove them.
- Take off the winch cover or motor housing. Depending on your model, this may involve removing screws or bolts. Keep track of all fasteners.
- Open the solenoid box. This is the electrical brain of your winch and often the most vulnerable part to water damage.
- Inspect all internal components. Look for rust, moisture buildup, dirt, or worn-out seals. If you see corrosion on electrical connections, clean them with a wire brush and apply a rust inhibitor.
At this point, you’ve identified weak spots that need sealing. Let’s move on to waterproofing.
Step 2: Seal the Motor Housing
The motor housing is the heart of your winch. If water gets inside, it can corrode the motor brushes, cause electrical shorts, and reduce performance.
How to Seal the Motor Housing:
✔ Apply RTV silicone sealant around all seams and joints. Use a high-quality RTV (Room Temperature Vulcanizing) silicone designed for automotive applications. This will prevent water from seeping through small gaps.
✔ Check for factory drain holes. Some winches have tiny drain holes in the bottom of the housing. If yours does, make sure they remain open so water can escape instead of pooling inside.
✔ Grease the motor shaft and bearings. Use marine-grade grease, which is designed to repel water and prevent rust. Apply a thin layer on all moving parts.
✔ Tighten all housing bolts. After sealing, secure the housing back in place to ensure an airtight fit.
By properly sealing the motor housing, you ensure that water stays out, even when submerged.
Step 3: Protect the Solenoid and Electrical Connections
The solenoid is the most vulnerable part of your winch. It controls power flow to the motor and is easily damaged by moisture. If water gets inside, it can cause short circuits and complete failure.
How to Waterproof the Solenoid and Wiring:
✔ Coat all electrical terminals with dielectric grease. This grease acts as a moisture barrier and prevents corrosion. Apply it generously to all terminals and connectors.
✔ Use heat shrink tubing on all electrical wires. Cut pieces of heat shrink tubing and slide them over the wire connections. Use a heat gun to shrink them down tightly.
✔ Wrap wires in electrical tape for added insulation. This provides an extra layer of protection against water and mud intrusion.
✔ Seal the solenoid box with RTV silicone. Run a bead of silicone around the edges of the solenoid box before closing it. This prevents water from seeping inside.
✔ Relocate the solenoid box (optional). If you frequently drive through deep water, consider mounting the solenoid box under the hood instead of leaving it exposed on the winch.
This step ensures that your winch’s electrical system remains fully functional, even in wet conditions.
Step 4: Grease the Winch Gears & Lubrication Points
Winch gears work under extreme pressure, and if they aren’t properly lubricated, they can seize up. Water and mud accelerate wear by washing away grease and causing rust.
How to Properly Grease Your Winch:
✔ Use marine-grade grease on planetary gears. Open the gear housing and apply a generous layer of grease to all metal gears. This reduces friction and protects against water intrusion.
✔ Apply grease to the clutch mechanism. The free-spool clutch is often neglected but can seize up if water gets inside. Coat the moving parts lightly with grease.
✔ Lubricate the winch drum and cable/rope guides. This ensures smooth operation and prevents rust buildup on exposed metal parts.
By keeping the internal components well-greased, you extend the lifespan of your winch and maintain smooth operation.
Step 5: Reassemble and Test the Winch
Now that everything is sealed and lubricated, it’s time to put the winch back together and test it.
How to Reassemble and Test Your Winch:
- Reattach the motor housing and solenoid box securely, making sure all seals are tight.
- Bolt the winch back onto the mounting plate. Ensure all mounting points are secure.
- Reconnect the electrical wiring. Double-check that all connections are properly sealed and insulated.
- Test the winch operation. Before taking it off-road, do a dry test:
- Engage and disengage the clutch to ensure it moves freely.
- Run the winch in both directions to verify smooth operation.
- Spray the winch with water and check for leaks.
If everything works correctly, your winch is now waterproof and ready for deep water crossings!
Bonus: Additional Waterproofing Upgrades
For extra protection, consider these upgrades:
✔ Use a winch cover. A neoprene winch cover protects against dirt, rain, and UV exposure when not in use.
✔ Install a breather tube. A vented breather tube helps equalize pressure inside the motor housing, reducing the chance of water getting sucked in.
✔ Switch to synthetic winch rope. Unlike steel cable, synthetic rope doesn’t rust, hold water, or trap mud inside.
Additional Waterproofing Upgrades
Want to take your winch waterproofing to the next level? Here are some extra upgrades:
Winch Cover for Extra Protection
A neoprene winch cover helps keep rain, dust, and mud off your winch when it’s not in use.
Breather Tube for Pressure Equalization
Adding a breather tube to the motor housing prevents pressure buildup and reduces the chance of water being sucked in.
Synthetic Rope vs. Steel Cable
If you’re still using steel cable, consider switching to synthetic winch rope. Steel traps water inside the strands and rusts over time, while synthetic rope is lightweight, floats on water, and won’t corrode.
Maintenance Tips for Keeping Your Winch Waterproof
Even with proper sealing, routine maintenance is key to keeping your winch in top shape.
✔ Inspect seals and connections regularly – Check for cracks or worn-out sealant.
✔ Reapply grease every few months – Especially if you off-road in wet conditions.
✔ Dry your winch after water crossings – Run it under load for a few seconds to evaporate any moisture inside.
✔ Check for condensation inside the housing – If you see moisture buildup, disassemble and dry out the internals.
Common Mistakes to Avoid
- Overusing silicone sealant – Too much can trap water inside instead of keeping it out.
- Ignoring electrical connections – Failing to grease and shrink-wrap them can lead to shorts and corrosion.
- Not testing after sealing – Always check your winch before relying on it in extreme conditions
Conclusion
A waterproofed winch can mean the difference between a smooth recovery and a nightmare scenario. By sealing the motor, protecting the solenoid, and lubricating key components, you can ensure your winch performs flawlessly, even in deep water crossings.
If you haven’t waterproofed your winch yet, now’s the time. A little preparation today can save you from a big headache later on the trail. Happy off-roading!
