The WARN ZEON XD is the next iteration of performance winches from Warn Industries. It's completely new from the ground up with great new features, outstanding performance, and top-tier dependability.

You may be wondering what the differences are between our Premium Series ZEON XD and our Standard-Duty VR EVO winches? Here, we'll look at the winches and what separates them apart.

Assembly Location

For starters, the ZEON XD is designed, engineered, tested, and assembled at the 200,000 sq./ft. ISO-quality-certified WARN facility in Clackamas, Oregon. There, 400 dedicated employees cut metal, shape gears, and work together to produce this winch alongside many other iconic WARN winches.

The ZEON XD is part of the WARN Premium Series of winches and is made with top-quality parts from all over the globe (much like how a car or truck is put together). And yes, many of the parts (such as gears) made in-house at our Oregon headquarters.

The VR EVO has been extensively tested in-house in Clackamas, OR and is made in China to Warn's stringent specifications. Over the years, the winch has become the best winch in its class and offers a host of great features for the money. If the VR EVO wasn't up to our standards, it wouldn't wear the Red W.

Winch Components: Fairlead, Rope, and Waterproofing

Being part of the WARN Premium Series of winches, ZEON XD is going to have higher-quality components throughout the product than VR EVO. (It's literally built to a different, more premium level.) Some of these premium components include a premium geartrain, OEM-grade black fasteners, a forged hawse fairlead, Spydura synthetic rope, and bus bars instead of external wires which connect the controls the motor. ZEON XD is also IP68 and IP69K waterproofed with more durable rubber O-ring seals than VR EVO.

ZEON XD fairlead on the left features forged aluminum with black anodized finish. The VR EVO on the right is built of cast iron with a black powdercoat finish.

The VR EVO is waterproof, but IP68 only (not IP69K) and uses a different kind of gasketing. While VR EVO is still built with quality parts, they're not to the level of the ZEON XD's. For example, its fairlead is cast iron and the rope is our standard-duty line (vs. forged aluminum and Spydura rope on ZEON XD). However, VR EVO allows buyers to choose between steel or synthetic rope; ZEON XD is synthetic rope only.

Drum, Brake, and Gear Train Differences

These winches have a difference in drums. ZEON XD features a one-piece large-radius cast aluminum-alloy drum with an ultra-strong through-drum rope attachment point. This larger diameter helps to extend the rope's service life. VR EVO has a more traditional, standard-radius welded two-piece drum and utilizes a puck with a set screw to attach the rope to the drum's flange.

When it comes to brakes, ZEON XD and VR EVO have brakes rated to hold the winch's full-rated load. The ZEON XD uses an extra-durable six-segment cone brake for the ultimate holding power and control. VR EVO uses a spring brake for holding duty. Both will hold the winch's full capacity under load.

ZEON XD gears on the left, VR EVO is pictured on the right.

Both ZEON XD and VR EVO use a smooth and reliable three-stage planetary gear train. However, the gear train on the ZEON XD is different from the VR EVO. It's more robust than the VR EVO with different materials and tolerances, providing greater reliability. Plus, the ZEON XD's gear set is rated at twice the durability of Standard-Duty winches.

Electronics

Both ZEON XD and VR EVO feature high-quality, waterproof Albright contactors for the ultimate in electronic reliability and control—a win-win. However, the ZEON XD houses its electronics in a metal control pack casing, which is connected to the motor using bus bars. Bus bars aren't only more efficient than external wires, but also provide a cleaner look. VR EVO utilizes traditional exterior wires from its impact-resistant composite control pack to the motor.

ZEON XD gears on the left, VR EVO is pictured on the right.

Both the ZEON XD and VR EVO feature a convertible control pack design allowing the pack to be remotely mounted away from the winch body. With ZEON XD, you'll need to purchase a separate relocation kit to do this.

Both winches include a corded remote (12' on ZEON XD, 11.5' on VR EVO). The ZEON XD's remote has an extra-durable ruggedized frame and is waterproof. ZEON XD also includes the WARN HUB Wireless Controller, allowing you to operate the winch using the Bluetooth connection on your smartphone from 100 ft. or more away.

The VR EVO includes a unique 2-in-1 corded and cordless remote allowing both tethered and wireless options. Additionally, VR EVO can use the HUB Wireless Controller, which is sold separately.

ZEON XD with synthetic rope only. VR EVO offers a choice of steel or synthetic.

Load Capacity and Rope

Both winches come in multiple capacities. ZEON XD is available in 10,000 lb. and 12,000 lb. capacities with Spydura Synthetic rope; VR EVO comes in 8,000, 10,000, and 12,000 lb. versions, with a choice of steel or synthetic rope. No matter which you choose, both have been extensively tested in-house by Warn at our Clackamas facility.

Performance

With its premium components, the ZEON XD is going to be a higher-performance winch than the VR EVO (which is still no slouch). But the combination of high-performance parts and improved gearing makes the ZEON XD significantly faster at zero load. Zero-load line speed is important because it allows you to respool your winch rope quickly after a recovery, getting you back on the trail faster.

For example, a ZEON XD 10-S has a no-load speed of 40 ft./min., whereas a VR EVO 10-S will pull 27.1 ft./min. The 12,000 lb. winches offer the same story with zero-load line speed on ZEON XD 12-S being 31 ft./min., and VR EVO 12-S offering 26.2 ft./min.

Overall, ZEON XD provides greater durability and a longer service life than a VR EVO due to the more premium components used in its construction.

Price

Being part of the Premium Series of winches, the ZEON XD will cost more than a VR EVO. ZEON XD's combination of American assembly and premium components simply cost more to produce.
VR EVO offers great value for a Standard-Duty winch, and it continues to lead the pack in its class.
Think of this as a good/better scenario. VR EVO is a good winch. ZEON XD is better. However, we stand behind both with the same warranty and service levels.

Both ZEON XD and VR EVO are backed by our US based customer service team.

Warranty, Replacement Parts, and Service Network

Whether you opt for a ZEON XD or a VR EVO, you'll have the same warranty as all our truck winches: limited lifetime on mechanical components and seven years on electrical items. Both winches offer a full line of service parts so they can be repaired vs being thrown out and replaced. And being genuine WARN winches, both are backed by a global service organization and our US based customer service team. So, no matter where you are in the world, there's a way to get WARN parts to keep your adventure going and the winch pulling.

Which Winch is Right for You?

We can't tell you which winch is right for you. On one hand, the ZEON XD is a no-compromise winch built with premium parts to stand up to the toughest winching challenges. On the other hand, the VR EVO is an excellent value with a host of great features and class-leading performance that won't break the bank.
In the end, the choice is yours. Regardless, you'll be backed by the leader in winches, Warn Industries, with over 76 years of off-road experience—and no other winch company can say that.