How To Install A Battery Relay Switch

[Bird Dog]

Completed the under hood electric prep for the new winch and thought I'd share my installation for others. I wasn't at all interested in a manual rotary switch that would require me to unlock and open the hood so I decided to go this route using a 500 amp relay and one of the factory aux switches. The 500A relay was purchased on Amazon and there were several options under $40.

I began with a piece of 1-1/2" aluminum angle from Lowes that was made into a bracket using some rivets and washers. After getting the shape I wanted it was sprayed with some black Flex Seal I had in the shop giving it a finished look. It was sized to fit next to the main battery and is secured using the two factory bolts shown. The relay is shown bolted to a small drop down off the main bracket so that it is positioned a little lower in the engine compartment ensuring that the hood would close without any clearance issues. The relay was connected to the main battery with an 18" #2AWG preassembled cable also sourced on Amazon. The 2 drilled holes left of the relay are used to secure the four aux switch leads with a cable tie.

It's connected it to the #4 aux switch. The relay is "electrically held" (ie: latched) meaning as long as the aux switch is "on" the coil in the relay is energized and closes the relay thus allowing power to flow through the device. When you are done operating the winch the aux switch should then be turned off. Switch settings are shown.

Pretty simple install. Most of time was spent making the bracket.

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[GAJTR]

Very nice work! I was thinking of doing something similar but I have my Voswitch box where you mounted the relay. Thanks for all the details!

 

[Chance575]

Just use an Anderson plug near the battery and leave it unplugged until you need to use the which

 

[Bird Dog]

Just use an Anderson plug near the battery and leave it unplugged until you need to use the which

Don't want to unlock and open the hood, then reverse the hassle, when I want to use the winch. That was the point of going this route. I'm lazy.

 

[Vetterestorer]

Beware

You may want to leave the solenoid on/engaged for about 10 minutes and see how hot it gets. I bought one like that on Amazon that said 500 amps in the write-up and it got super hot when on/latched with no load and the winch not operating. Too hot to touch. I returned it at bought the genuine Warn solenoid. The Warn solenoid stays cool to the touch when latched. However, it is configured differently with the cables connecting on the sides instead of the top (the Warn is like a standard starter solenoid) and it did cost twice as much.

I also used one of the low amp aux switches to trigger the relay.

 

[ShadowsPapa]

Completed the under hood electric prep for the new winch and thought I'd share my installation for others. I wasn't at all interested in a manual rotary switch that would require me to unlock and open the hood so I decided to go this route using a 500 amp relay and one of the factory aux switches. The 500A relay was purchased on Amazon and there were several options under $40.

I began with a piece of 1-1/2" aluminum angle from Lowes that was made into a bracket using some rivets and washers. After getting the shape I wanted it was sprayed with some black Flex Seal I had in the shop giving it a finished look. It was sized to fit next to the main battery and is secured using the two factory bolts shown. The relay is shown bolted to a small drop down off the main bracket so that it is positioned a little lower in the engine compartment ensuring that the hood would close without any clearance issues. The relay was connected to the main battery with an 18" #2AWG preassembled cable also sourced on Amazon. The 2 drilled holes left of the relay are used to secure the four aux switch leads with a cable tie.

It's connected it to the #4 aux switch. The relay is "electrically held" (ie: latched) meaning as long as the aux switch is "on" the coil in the relay is energized and closes the relay thus allowing power to flow through the device. When you are done operating the winch the aux switch should then be turned off. Switch settings are shown.

Pretty simple install. Most of time was spent making the bracket.

Well done. Similar to how I did mine with the Warn solenoid switch. Also run by aux switch. And my switch settings match yours.

Which solenoid switch did you go with? Considering upgrading since I would be stripping my 2022 and starting all over with a 2025. I tend to keep making changes and improvements as I go - always have done things that way. I keep seeing ideas (like yours) and things I could do better "next time".

Anyway - nice.

 

[Vetterestorer]

The Warn Solenoid:

https://www.amazon.com/dp/B000OV4NT4?ref=ppx_yo2ov_dt_b_fed_asin_title

 

[ShadowsPapa]

The Warn Solenoid:

https://www.amazon.com/dp/B000OV4NT4?ref=ppx_yo2ov_dt_b_fed_asin_title

That's the exact one I have - I used auxiliary switch 3 as it has more than enough ability to handle a solenoid primary.

 

[Vetterestorer]

Yes, mine is similar to yours. I placed it about 4" closer to the cab on the same type of fender mount.

 

[Bird Dog]

Beware

You may want to leave the solenoid on/engaged for about 10 minutes and see how hot it gets. I bought one like that on Amazon that said 500 amps in the write-up and it got super hot when on/latched with no load and the winch not operating. Too hot to touch. I returned it at bought the genuine Warn solenoid. The Warn solenoid stays cool to the touch when latched. However, it is configured differently with the cables connecting on the sides instead of the top (the Warn is like a standard starter solenoid) and it did cost twice as much.

I also used one of the low amp aux switches to trigger the relay.

Thanks for the heads-up. Will definitely keep an eye on it. Shouldn't be a big deal to switch to the Warn relay if needed. Now if Grimm will just ship their winch plate I can finish the install.

 

[Blade1668]

The Warn relays last a long time too even in harsh use. One that was in my XJ worked for about 15 years or so. It was exposed to swamp water brackish water, and snow and ice too. But did give up due to corrosion. I replaced with another one and used same type in my JT and aux switched. Same mounting method as you and "ShadowPapa"

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