Pierce PS654 Series Winch Maintenance

In this how-to article we cover the step by step process for maintaining all the Pierce PS654 series winches. Winch Maintenance Pierce PS654 series:



Evenly Spooled:

Your cable must be spooled up on the drum evenly. Not too much to on one side, and not too much in the middle. Spool it across evenly and wrap it back across the other way.

Light Lubricant:

For maintenance on your cable keep a light penetrating lubricant oil. This will keep your cable soft and keeps it from corrosion.

Beware of Extreme Angles:

Keep away from extreme angles as this could cut your cable.


You have oil in two separate housings. This is your main gear housing, this is your transfer housing.  Each housing will hold 8 to 12 ounces. Use 20% Lucas HD oil stabilizer and 80% 15w-40 oil.

Replace Gaskets and Seals:

The only maintenance you will have to do here is if you’re leaking you will need to replace your seals and gaskets.

Change Oil Yearly:

Change the oil periodically, maybe once a year or so. Change the oil more frequently if you use your winch heavily.

Run your Winch Periodically

You do want to run your winch every so often. Every thirty days spool out the cable about five feet to keep all the contacts in the motor good. It will also keep your cable fresh. If your winch just sits your contacts tend to stick from corrosion. This could actually rip parts of the armature off. So you will damage your winch from neglect if you do not run it occasionally.


You have your main power wire coming from your solenoid assembly. This will run to a cutoff switch like our PS025. Then you will run from that switch back to the positive terminal on the battery.

Use Rubber Conditioner:

You can use a rubber conditioner to make sure you don’t rot your coating. Make sure everything is clean.

Replace Corroded/Frayed Wiring:

You will want to make sure there are not cuts or frays in your wire. You can always arc or short out against your frame or anywhere this is run so always make sure there are not cuts on your wires.

Ensure Tight Connections:

On your terminals you want to make sure you have a good tight connection at the switch, battery or whatever you are hooked up.

We also recommend dielectric grease to help prevent corrosion. Use the grease on the power side. For a ground use one of these three bolts.

Terminals Are Not Grounds:

Don’t use the motor as the ground. No terminals are grounds, just these three bolts.  

These are the grounds that you will need. It will need to be the same size as your power wire at least a number four if not a number two. This will go directly to the negative terminal on the battery, not to the frame.

On your wires going to your motor from your solenoid assembly you have three wires and three terminals. You will notice these wires are about the same size as your power wire. You want to make sure you condition them so they do not rot. Make sure there are no cuts, no frays, and as the terminals on the motor make sure they are tight and corrosion free.

Remote Plug 

On your plug maintenance you will notice that there are 4 (four) terminals. Each one of them is actually made up of two pieces. Over time these pieces will compress. You can get a small flat tip screw driver and spread them out just a little bit. That will make a good connection on your remote.

There is a little bit of grease in there that’s the dielectric grease. You can always use that to keep any type of corrosion out and to keep water off of your terminals.


On the other side all you have is grease. You have two grease inserts and you will want to grease these periodically. If this ever runs dry, especially up north where a lot of salt is used to melt the ice and snow it will freeze up. Your free spool capabilities will be gone. The only thing you can do is to use an anti-seize or you may have to replace the entire housing.

To grease these get a grease gun. You put it on each of the grease inserts and you will want to pump enough grease until you start seeing grease seep out between the clutch handle and the housing. On the other side you will see it seep out where the clutch lever ends.

Watch the full video below for visual instructions on maintaining your Pierce winch.

Please note: This is intended to be a maintenance overview, not an exact step by step process. Are you wondering how to properly complete maintenance on your winch motor? Read on or watch the video below.

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