How to Replace Your Steel Winch Cable with Synthetic HMPE Line
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If you’re still running steel cable on your winch, it might be time for an upgrade. Synthetic winch line made from HMPE (High Modulus Polyethylene) is lighter, safer, and easier to handle—and it won’t snap back with deadly force like a broken steel cable. But before you simply bolt it on and spool it up, there are a few critical steps you must take to protect your investment.
Installing synthetic line on a winch that previously used steel without proper prep can cause premature damage, rope failure, or worse. Here’s how to make the switch the right way.
1. Replace or Inspect the Fairlead
Steel cable beats up fairleads over time, especially roller fairleads or standard aluminum hawse fairleads. Those grooves and burrs? They'll shred synthetic rope on your first pull.
Solution: Swap your old fairlead for a smooth aluminum one specifically made for synthetic rope—like our Groove Fairlead, designed to reduce friction and keep your line gliding safely through every recovery.
2. Clean the Winch Drum
Steel cable leaves behind a mess—rust flakes, embedded burrs, and sharp metal bits stuck in the drum or lip. Any of those will chew into your synthetic line and cause serious damage.
Solution: Remove the old cable and sand the drum smooth. Pay close attention to the edges of the drum and any corrosion or scoring. Your goal is a clean, burr-free surface before installing synthetic.
3. Inspect for Pinch Points or Sharp Angles
Steel cable is tough and can power over worn-out tie-off points and jagged drum flanges. Synthetic rope? Not so much. It needs a smooth, consistent path to operate safely.
Solution: Closely examine the winch housing, tie-off points, drum flanges, and internal guides. If you feel any rough spots with your fingers, your rope will feel them too—and fray.
4. Switch to a Soft Shackle
Old-school setups often use heavy metal hooks that aren’t compatible with synthetic rope. The eyelet might be too tight, or there could be burrs that cut into the fibers over time.
Solution: Retire that steel hook and grab a Yankum soft shackle. It’s safer, lighter, and built specifically for synthetic line—and pairs perfectly with our Groove Fairlead.
5. Check the Drum End for Compatibility
Steel cables are usually swaged or crimped onto the drum. Synthetic lines, on the other hand, typically use a soft eye that bolts into the drum or anchors with a tab. You’ll need to confirm that your winch supports this attachment method.
Solution: Inspect your drum’s anchor point. If it’s not compatible, upgrade it with a drum insert or synthetic-friendly anchor tab. Most winches can be retrofitted with simple bolt-in options.
Before installation, you’ll also want to taper the end of your synthetic line to make feeding it through the drum hole easier and to reduce bunching or fraying. Need help with that process? Check out our full step-by-step guide here:
How to Taper the End of a Synthetic Winch Line
Final Swap-Out Checklist
| Step | Action |
|---|---|
| Fairlead | Replace with smooth aluminum hawse |
| Drum | Clean and de-burr |
| Sharp Edges | Check housing and rope path |
| Hook | Switch to a soft shackle |
| Drum End | Confirm or upgrade anchor method |
Upgrading to synthetic isn’t just a gear swap—it’s a performance and safety boost. But only if done right. Clean it up, swap the parts, and you’ll be set for smoother pulls and peace of mind.
Ready to make the switch?
Shop Yankum’s synthetic winch line, fairleads, and soft shackles now
