What Is the Difference Between Steel and Synthetic Winch Rope, and Which Should You Choose?

Synthetic rope is a great product if you winch frequently and are concerned about weight. It is lightweight and easy to handle, doesn't develop sharp burrs like steel rope, and doesn't store as much potential energy when under load. On the flip side, synthetic rope is more prone to abrasion, and should be regularly inspected for frays or damage caused by UV light, chemicals, and overall use.

Steel rope is extremely durable, and is good for both vehicle recovery and utility work, such as moving trees, rocks, etc. Ultra-violet wear is also not a factor with steel rope, and it may be a better choice if you don't use your winch very frequently. Steel rope is heavier than synthetic, can develop rust, and can also develop sharp burrs. This is one reason why we always recommend users wear heavy gloves to protect their hands while handling the rope.

Some people automatically think synthetic rope is safer than steel rope. Although steel rope will store more potential energy, since it's made out of steel, it is less prone to abrasion and possible fraying. The bottom line is that no matter which rope you choose, you need to follow safe winching techniques.

Read our blog post or watch a video on the topic.

Why Is It Necessary to Stretch Your Winch Rope?

Stretching winch rope is a critical step to setting up your winch, whether you have a truck or powersports winch, steel or synthetic rope. When you get your winch, the rope is either not on the drum or it's simply been wrapped around the drum, but not under tension. Stretching the rope under tension allows you to evenly place the rope onto the drum, and when done correctly, will prevent the rope from bunching up onto itself and, when under load, potentially crushing the rope beneath itself and damaging the rope. The video below will show you exactly how to do it.

You can read step-by-step directions in this blog post, or watch the video below.

What Are the Parts of a Winch Rope?

Get to know the parts of your synthetic rope:

1. Rope Hook — Attached to the rope thimble at the end of the winch rope. Used to secure the rope to the load, vehicle, or anchor point. Rated based on the capacity of the rope and the winch.
2. Rope Thimble — Protects the synthetic rope from pinching and abrading where it comes in contact with the hook.
3. Abrasion Sleeve — Provided with the synthetic rope and must be used at all times to protect the rope from potential abrasion wear. The sleeve has a loose fit so it can easily be repositioned along the rope to protect from rough surfaces and sharp corners.
4. Heat Sleeve — Made with a high temperature resistant material. Protects the outer layers of the synthetic rope from brake heat generated during normal winch use.
5. Rope Eyelet — The attachment point of the rope to the winch drum.

When Do You Need to Replace Your Winch Rope?

Always inspect winch rope, hook, and slings before operating your winch. Frayed, kinked, or damaged winch rope must be replaced before operation. You should never use a winch rope that has been compromised in any way, whether it's synthetic or steel.

See the following examples of synthetic winch rope damage:

1. Rope with original bulk, no damage.
2. Rope displaying 25% strand volume reduction from abrasion — rope should be replaced.
3. Rope strand showing full volume.
4. Rope strand reduced by 25% abrasion — rope should be replaced.
5. Rope exhibits fiber-set from compression. A slight sheen is visible. This is not a permanent characteristic and can be eliminated by flexing the rope.
6. Rope displays two adjacent cut strands — rope should be replaced.

Steel rope, while durable, can still be damaged. Watch for damage such as crushed rope, kinked rope, heavy rust, or corrosion.

Can You Upgrade a Winch From Steel Rope to Synthetic?

Yes, but there are a few considerations when upgrading winch rope.

1. You will need to change from the standard roller fairlead used on winches with steel cable to a smooth, hawse fairlead to avoid damage to synthetic winch rope.
2. You need to make sure the winch rope weight capacity matches the winch weight capacity. We provide replacement rope part recommendations for WARN winches. Please check our rope replacement chart.
3. Review the rope installation manual for your winch — see the links below.
4. Ensure your new rope is the same length and diameter as your previous rope. Heavy duty ropes are often thicker than standard duty ropes, which can affect how long of a rope can fit on a winch.