8.1 Winch¶

Model: Warn Zeon 10-S

Mounting Location: Front bumper (verified compatible)

Pulling Capacity: 10,000 lbs (4,536 kg)

Motor: 12V DC series wound

Product Image:

Warn Zeon 10-S Winch

Electrical Specifications¶

Peak Amperage Draw: 409A (at full load/stall - brief periods only)¹
Typical Operating Draw: 80-250A (most recovery operations)
Main Power Source: AUX battery (passenger rear wheel well - direct connection, no fuse/breaker)
See AUX Battery Distribution for wire specs (gauge, length, routing, voltage drop calculations)
System Voltage: 13.8V (alternator charging - engine running during winch operations)
Protection: None - direct connection (see justification below)

Circuit Protection¶

No external circuit breaker — per the WARN ZEON 10-S installation manual. Protection: integrated thermal cutoff, contactor isolation (emergency shutoff: disconnect at battery terminal), and 1/0 AWG cable (adequate for 409A brief peaks). Automotive practice (SAE J1128) differs from marine (ABYC E-11), which fuses all circuits. See Standards Exceptions.

Contactor/Solenoid¶

Type: Warn Zeon 10-S integrated contactor (included with winch)
Location: Mounted on winch motor housing
Rating: Rated for full stall current (≥409A switching)
Function: High-current switching for winch motor direction and power

Control System¶

Dual Control Setup: Dash rocker switch + handheld remote (both work simultaneously)

Dash Rocker Switch:

Type: Center-off momentary rocker switch (SPDT or DPDT)
Location: Dashboard physical switch panel
Function:
UP (momentary): Winch OUT (let out cable)
CENTER: Off (spring return to center)
DOWN (momentary): Winch IN (pull in cable)
Power: BODY PDU CB43 (10A)
Use case: In-cab winch control (self-recovery, convenient operation from driver seat)

Handheld Remote:

Type: Warn factory wired remote (included with Zeon 10-S)
Function: IN/OUT directional control (same as dash rocker)
Connection: Plugs into winch control pack
Use case: Outside vehicle spotting (traditional winch operation with visual line of sight)

Wiring¶

Main Power Wiring:

See AUX Battery Distribution for wire specs (gauge, length, routing path).

Positive (+): AUX battery+ → winch contactor → winch motor (direct, no breaker)
Negative (-): AUX battery- → winch motor ground lug

Control Wiring:

Power Source: BODY PDU CB43 (10A fuse) - sourced from Firewall CONSTANT Bus (AUX battery)
Dash Switch: CH4X4-TOY-D-WINIO dual-momentary push, Toyota-style (1.54" × 0.83" cutout) - see Dashboard Controls
Signal Path: BODY PDU CB43 → CH4X4 switch (push IN or OUT) → HDP24 pins 16/17 → winch contactor IN/OUT triggers
Remote: Wired in parallel with dash switch at contactor IN/OUT trigger terminals
Wire Gauge: 18 AWG (low-current trigger signals, ~2A max each direction)
Routing: BODY PDU (firewall cabin side) → ~3 ft to dash switch → out through HDP24 → engine bay → winch contactor (front bumper)

Circuit	Source	Protection	Wire Gauge	Destination	Function
Main Power (+)	AUX battery+	None (direct)	See AUX Battery Distribution for wire specs	Winch Contactor → Motor	High-current power
Main Power (-)	AUX battery-	None	See AUX Battery Distribution for wire specs	Winch Motor Ground	High-current return
Trigger IN	CH4X4 IN button	BODY PDU CB43 (10A)	18 AWG	Winch Contactor IN trig	Low-current trigger
Trigger OUT	CH4X4 OUT button	BODY PDU CB43 (10A)	18 AWG	Winch Contactor OUT trig	Low-current trigger
Remote Control	Warn Remote	Internal to winch	Per Warn specs	Winch Control Pack	Parallel to dash

Installation¶

Power Cable Routing:

See AUX Battery Distribution for cable specs and routing path.

Route: Passenger rear wheel well → front bumper (~13 ft, exact path: Resolved — the winch ground return is the 1/0 AWG (−) conductor of harness H1, routed up the passenger rear sill and forward along the inside floor/side wall (fully inside the body, no exposed… #106 - avoid exposed frame rail per offroad protection requirement)

Outstanding Items¶

High (1)

ARB RD140 fitment with Revolution F10.25-513L in the Sterling 10.5 housing (#300) — The rear runs a 10.25" ring gear (Revolution F10.25-513L) in the 10.5 housing with the ARB RD140 carrier (Ford 10.25/10.5, 35 spline, all ratios). Confirm with ARB or Revolution that the RD140 flange and ring gear bolt pattern match the F10.25 gear in this housing before ordering, and confirm the pinion depth starting point (owner note: add roughly 0.120" to the pinion depth stack).

📋 Medium (3)

Air locker air line service loop length at full droop (front and rear) (#303) — Measure the ARB air line service loop needed at each axle at full droop on the ORI struts (14" front, 16" rear travel), not at ride height. Sets the air line kit segment lengths from the manifold under the passenger seat (baseline estimates ~12 ft front, ~6 ft rear).
Front Air Locker Solenoid Routing (#81) — Path for 18 AWG (~12 ft) from SwitchPros OUTPUT-17 (passenger rear wheel well) to front axle solenoid - cross-cab + forward
Winch Trigger Control Routing (#80) — Path for 14 AWG control wire (~13 ft) from SafetyHub ATC-1 (passenger rear wheel well) to winch contactor (front bumper)

AUX Battery Distribution - Winch power source (passenger rear wheel well)
Wire Distance Reference - Winch to battery routing distance (13 ft one-way, 26 ft circuit)
SafetyHub - Winch contactor trigger circuit protection
Air Compressor - ARB compressor for tire inflation

Model confirmed WARN ZEON 10-S (owner, 2026-05-30) — the earlier "ZEON 10-S" naming was incorrect. WARN's published peak draw for the ZEON 10-S is 409A @ 10,000 lb (pull table: 62/144/215/280/353/409A); the previously documented 450A (≈ ZEON Platinum) was conservative. 1/0 AWG cable and the integrated contactor retain margin above 409A; WARN service battery leads for the 10-S are 2 AWG (our 1/0 AWG is a deliberate upsize). Source: WARN ZEON 10-S (89611) (checked 2026-05-30). ↩