Warn's New Zeon Winch

1302Or 01 Warn Zeon Winch Zeon 12 Installed On Ford Truck

So, just how do you reinvent the wheel? Well, that’s easy: Make it lighter, stronger, and better looking! that’s how we’d do it, anyway. Warn Industries decided to improve the construction of winches by innovating an all-new design to once again set the industry standard--something they’ve been doing since 1948. Since we’re pretty good at getting stuck off road, we’re always interested in the latest and greatest in recovery equipment. so, we jumped at the opportunity to get a firsthand look at Warn Industries’ newest product when they invited us up to their factories in Portland, Oregon, (which employs more than 500 workers) for the unveiling of their top-secret project. The Zeon line of truck and SUV winches are like nothing you’ve ever seen before!

The Warn Zeon winch features a full cast-aluminum housing for lighter weight and superior strength throughout. Not only does it feature an all-aluminum chassis, it also features a heavy-duty 3.15-inch aluminum drum spool to help dissipate heat under severe winching duties. After seeing the Zeon in action, pulling several trucks up steep hills (and even a tractor out of a mud pit), we can tell you it has plenty of pulling power and stays relatively cool to the touch—even under constant heavy winching—but one of the coolest things is just how quiet the new series wound motor is. There’s no doubt that the Warn Zeon winch is going to raise the industry standard again.

You’ll notice in this cutaway of the Warn Zeon that the electrical brushes are mounted inboard closer to the aluminum drum to work as a giant heat sink. The new series wound motor also has ridges all around to improve cooling under heavy usage. You’ll also notice that the whole chassis is constructed out of cast aluminum for greater overall strength as well as longer run times and faster cool-down times. The Zeon also has no exposed electrical wires as the control box connects to the motor via thick copper buss bars to ensure a solid electrical connection.
You’ll notice in this cutaway of the Warn Zeon that the electrical brushes are mounted inb
The new large aluminum winch drum measures 3.15 inches in diameter and is designed to reduce rope wear and also has an integrated rope anchor for easy rope installation and servicing.
The new large aluminum winch drum measures 3.15 inches in diameter and is designed to redu
The newly designed geartrain features thicker gear plates as well as wider gear faces and six carrier pins as opposed to the three used in previous models. This allows for faster line speeds as well as quieter operation while still employing the use of a tried-and-true three-stage planetary gearset.
The newly designed geartrain features thicker gear plates as well as wider gear faces and

One of the coolest parts about the Warn Zeon winch is that it features a convertible control box that can be removed and mounted remotely under the hood to give it a clean low-profile look. We were very impressed with the looks of the Zeon and we think the satin-black finish really brings together the overall appearance. The Zeon is available in 8,000-, 10,000-, or 12,000-pound steel cable versions, as well as 8,000- and 10,000-pound synthetic rope versions. The Warn Zeon winch line also uses five stainless-steel motor cap bolts instead of two for better sealing against the elements and has an IP68 rating, which means it remains watertight under three feet of water for at least 30 minutes. What more could you ask for?
One of the coolest parts about the Warn Zeon winch is that it features a convertible contr
Here you can see the larger stainless-steel clutch engagement handle that engages the rotating ring gear for free spooling. The ergonomics of the new handle are a clear cut above anything currently out on the market.
Here you can see the larger stainless-steel clutch engagement handle that engages the rota