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ProMark Offroad Blog

Recovery Winch Ropes: Synthetic or Steel Cable?

Recovery winch with synthetic rope

Synthetic rope is safer than steel cable.

When recovery winches first came out on the market, they all came with steel winch cable. Now there’s a new kid on the block: synthetic winch rope. While some offroaders are skeptical of the long-term durability of synthetic rope, others have made the switch and say they’re never going back.

Winch Rope Safety

What’s so special about synthetic winch rope? The biggest advantage, according to most offroaders, is safety. While steel winch cable can snap back violently if it breaks, synthetic rope is lighter and stores less kinetic energy, which means that it doesn’t go very far if it snaps.

We’ve all heard stories about steel cable shattering windshields or causing serious injuries. No one wants that to happen when they’re out for a trail ride…especially if the kids are along. Synthetic winch rope makes recovery operations safer.

Advantages of Synthetic Rope

Besides safety, there are other reasons you might choose synthetic rope over steel cable. Synthetic winch rope is lightweight (less weight hanging off the front of your Jeep), flexible, floats in water, and is easier on your hands—no barbs, no freezing, and no burning.

What About Steel Cable?

Is steel cable ever preferred over synthetic? Yes, if you mainly use your recovery winch for utility tasks like yard work, landscaping, and farm chores. Wire cable holds up better under abrasive conditions.

Synthetic Rope Care

Synthetic winch rope is more expensive than steel cable and requires more care. The synthetic fibers should be protected from the sun (excessive UV exposure can break down the fibers), and you should never leave the rope muddy or wet when spooled on the drum.

Tips for Using a Recovery Winch Rope

Winch rope

The winch rope should spool in tight, even rows onto the drum.

1. Don’t spool out all of the cable.

Always keep at least 5 wraps on the drum. Leaving a few wraps on the drum helps anchor the winch cable in place. The rope attachment to the drum is not designed to hold a load by itself.

Expert Tip: If your cable is too short, choose a closer anchor point, use a longer tree strap or chain, or hook up a cable extension.

2. Avoid continuous side pulls.

They place a strain on your recovery winch and allow the rope to pile up on one end of the drum. If the rope gets pinched in the winch housing, your rope or winch could be damaged.

Expert Tip: As much as possible, rig up the pull in a direct line from the stuck vehicle. Use a pulley block to redirect the pull if needed.

3. Avoid shock loads.

Use the winch remote to take up any slack in the rope. The rope should be under tension before beginning the winching process. Shock loads can momentarily exceed the winch rating, which is dangerous for your equipment and for any bystanders.

Expert Tip: Pulse the winch remote intermittently to wind the rope until no slack remains.

4. Watch how the winch rope spools onto the drum.

Don’t let it pile up on one side or get nested into the inner layers. The winch cable should spool in tight, even rows across the drum.

Expert Tip: If the cable stacks unevenly on one side of the drum, spool out the uneven section of rope and reposition it to the opposite end of the winch drum.

5. Never use a winch rope for towing or snatching another vehicle.

Use a snatch strap to free a stuck vehicle with a shock load, and use a tow rope to tow another vehicle at a slow, steady pace. A winch rope is also not meant to hold a load in place.

Expert Tip: Snatch straps are stretchy (to handle shock loads), while tow ropes do not stretch (to pull another vehicle behind you).

ProMark XTR 3000 Winch on a Bighorn UTV

Thanks to one of our customers for sending in this picture of a ProMark 3000 lb XTR winch with synthetic rope installed on the front of his Linhai 300cc Bighorn UTV! We think it looks pretty darn good…and the ProMark sticker is a nice touch, of course.

Bighorn UTV

Bighorn UTV with a 3000 lb ProMark winch

Choosing Synthetic or Wire Winch Rope

Synthetic winch rope

Synthetic winch rope is lighter and safer than steel cable.

Whether you’re looking for a new winch or replacing a damaged winch rope, one of the choices you need to make is whether to get a wire rope or synthetic cable. Wire rope is the most widely available choice, and it’s been in use for a long time. Synthetic cable is newer to the offroad scene, but it’s quickly growing in popularity. Here are some of the pros and cons of wire and synthetic rope.

Types of Use

If you’re planning to use your winch mainly for utility tasks (yard work, landscaping, farm chores, and the like), you’re better off with a wire cable. Wire holds up better under abrasion.

If you use your winch mostly for mudding and creek bogging, synthetic is the better choice. It’s lightweight, easy to handle, and floats in water.

Safety

One of the biggest drawbacks for steel cable is the fact that it holds so much tension. If the cable gets damaged and snaps, it can backlash violently, damaging anything or anyone in its path. That’s why experts recommend dampening the winch line with a heavy blanket, coat, chain, or tree branch. The extra weight slows the cable down and reduces the backlash effect.

Synthetic cable, on the other hand, doesn’t store the same amount of energy as steel, so even if the synthetic rope breaks, it rarely causes damage. It’s a lot safer for you, for your equipment, and for the people who ride with you.

Price

Wire rope is cheaper than synthetic rope, but depending on how much you value the safety and advantages of synthetic rope, the extra cost is more than worth it. If possible, ask a friend with synthetic rope if you can try out their winch. Ask what they like and don’t like about using synthetic rope. Their experience can help you make the decision between wire and synthetic winch rope.

ProMark Now Offering Recovery Winch with Synthetic Rope

Midnight recovery winch with synthetic rope

Midnight recovery winch with synthetic rope

Looking for a recovery winch line that’s safer and easier to handle? Take a look at the new Midnight Series recovery winches with a synthetic rope package.

While most truck and Jeep winches sold on the market require you to purchase and install synthetic rope in place of the pre-installed steel cable, ProMark Offroad saves you the added expense of buying a synthetic rope and aluminum hawse separately. The Midnight Series recovery winch synthetic rope package comes with pre-loaded synthetic rope and an aluminum hawse instead of steel rollers.

Synthetic winch line is lighter than steel cable, floats in water, won’t rip up your hands with barbs or stray wires, won’t freeze or burn your hands, and won’t snap back violently if it breaks. Want to give it a try? Find out more about ProMark’s new Midnight Series winch with synthetic rope.

Available in the following winch models:

  • 8000 lb winch
  • 9,500 lb winch
  • 10,000 lb winch
  • 12,000 lb winch

ProMark Outback Winches Now Available with Synthetic Rope

Outback synthetic winch

Outback winch with synthetic rope

The popular Outback Series winches are now available with a synthetic rope package. This package includes an aluminum hawse fairlead and ProMark Blue synthetic rope, pre-installed on the winch.

The Outback Series 12-volt electric winch is designed for large ATVs and side by sides. The heavy duty motor is waterproof for reliable performance in wet or muddy conditions. All metal gears keep your winch running smoothly for years of use. This winch package also comes with a 10-foot corded remote for convenience and safety.

The 3500 lb, 4000 lb, and 4500 lb Outback winches include the following:

  • Limited Lifetime Warranty
  • ProMark Blue Synthetic Winch Line
  • Waterproof Motor
  • 4-Post Contactor
  • Handlebar Thumb Switch
  • Aluminum Hawse Fairlead
  • Spring Hook and Pull Strap
  • Rubber Line Stopper
  • Bonus 10′ Corded Remote

Prevent Winch Rope Failure

Winch rope

Winch rope must be underwound on the drum.

Winch rope failure is most often caused by operator error. There’s a lot to know about how to safely operate a winch and take care of your winch rope. One small oversight can lead to winch failure or rope failure.

Causes of Winch Rope Failure

One of the most common causes of rope failure is friction. Overloading the rope is possible but less likely. You can usually tell the reason for the rope breaking by examining the cut ends. If most of the rope fibers are cleanly cut, the culprit is friction—for example, rubbing on a sharp rock or the edge of the winch plate. If the rope fibers are stretched out in long, thinning frays, the culprit is overloading. Sometimes you’ll see a combination of both, in which case a majority of the strands are cut by friction and the rest are frayed by the resulting overload.

Winch Rope Spooling

To prevent damage to your winch rope, make sure the rope is spooled onto the drum in the underwound direction. When the rope comes off the winch drum, it should be coming from underneath the drum, not on top of it. If the rope comes over the top of the winch drum, it will go through the fairlead at an angle, which leads to friction and possibly cutting. If the rope comes out from underneath the drum, it will go through the fairlead straight on, which eliminates friction and cutting.

Angle Pulls

Sharp angle pulls are another possible hazard for your winch rope. Straight pulls prevent the rope from rubbing on the sharp edges of a winch plate or bumper, but if an angle pull is your only way out, make sure the rope is not rubbing against anything. Same thing with sharp rocks. Don’t let the rope fray on a rock or other sharp object while you are winching. Use a rope sleeve to protect the rope.

ProMark Synthetic Winch Rope Featured in Four Wheeler Magazine

Look for ProMark Offroad’s synthetic rope for recovery winches featured in the July 2011 edition of Four Wheeler magazine!

The 92-foot ProMark Blue Synthetic Rope is safer, lighter, and up to 15 times stronger than traditional wire cable. Tired of dealing with burrs, kinks, and permanently coiled wire? Synthetic rope is easy on your hands and flexible for better handling. Unlike steel cable, it will not recoil violently if broken. ProMark synthetic winch rope is UV-coated for long life, easily spliced, and floats in water.

For more information, see the product page for the ProMark Blue 92′ Synthetic Rope.

Four Wheeler magazine

Check out ProMark's feature in Four Wheeler Magazine!

Can I Attach a Snatch Strap to a Winch Cable?

Winch rope

Unlike a snatch strap, winch rope is not designed to stretch.

If you’re short on winch cable, you might be tempted to hook up a snatch strap for an extension, but this can be a dangerous fix. Snatch straps and winch cables (wire or synthetic) are made for different purposes.

Snatch Straps

Snatch straps are designed to stretch and be able to handle shock loads. They can handle enormous amounts of force but only for the second that it takes to yank out a stuck vehicle. Then they immediately return to their normal length. Holding a snatch strap steady at its peak rated load can render the strap useless if it stretches to the point that it will no longer return to normal length.

Winch Cables

Winch cables are designed for steady pulls that require little or no stretch. For winch recovery, it’s important that the cable has no stretch for two reasons: 1) any stretch in the rope means that it takes more length of rope before the stuck vehicle will move, and 2) if the cable breaks, it will be less likely to act as a slingshot for shackles, snatch blocks, and other metal winch accessories. Because a winch cable has little or no stretch, it can easily be damaged by shock loads.

Using a Snatch Strap as an Extension

What happens when you connect a snatch strap to a winch cable? Combining these two materials increases the danger of the recovery process. If the winch line were to break, the snatch strap with its elastic nature could greatly increase the danger of projectiles, such as a D-shackle. The strap and cable have different breaking points, which complicates the amount of force that your recovery gear can handle.

In the end, it’s best to avoid combining a snatch strap and winch rope, both for the safety of people nearby and to avoid damaging your vehicle. Stick to safe and recommended techniques for winch recovery.

How to Replace a Winch Cable

ATV winch

Replace the cable on your winch with the same diameter and length.

When replacing the cable on your ATV or recovery winch, use the cable width and length recommended by the manufacturer. Never replace cable with heavier or lighter rope. If the cable is too thick, you won’t be able to fit as much cable on the spool. If it’s too thin, it won’t have enough strength for the load rating on the winch.

If preferred, you can switch to synthetic rope for safer winching, plus no frayed wire or kinked cable.

You do not need to remove the winch from the vehicle (unless the winch is mounted in a way that restricts access to the drum) or take the winch apart to replace the cable.

How to Replace Wire Winch Cable

  1. Spool out the entire length of the old cable.
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  3. Remove the winch cable where it is attached to the drum. Release the tension on the cable and push on the end of the cable where it feeds through the small hole in the drum. If the rope is kinked over and pulled tight into the drum, simply push the cable out of the hole until you can straighten out the kinked cable. Then pull the end of the cable through the hole to remove it from the drum. If the cable will not come out by pushing, try using a pin punch (or something similar) and a hammer to drive the metal button or keeper out of the hole. If your cable is attached to the drum with a bolt, you’ll need to remove the bolt to take off the cable.
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  5. Attach the new cable to the drum. For wire rope, slip the end of the cable through the hole in the drum and tighten the set screw to hold the cable in place. For recovery winches, apply Loctite (or similar product) to the cable clamp thread to prevent loosening of the screw. Tighten the clamp screw (but be careful not to overtighten).
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    If you are replacing your wire cable with synthetic rope, push the end of the rope into the hole in the drum. Pull the rope through the hole, wrap it around the underside of the drum and over the top, tuck the rope underneath itself where it exits the drum, and then depress the end of the rope back into the hole in the drum. You may need to use a screwdriver to force the end of the rope into the hole.

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  7. Respool the cable in the underwound direction so that the winch spools in and out correctly. Respool under a load of at least 500 pounds so that the outer layers will not draw down into the inner layers.
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