Warn winch bumper installation (revised)

PARAGON · #1 09-27-2004, 02:50 PM

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I started a new thread on the install so that I
could make some additions to my notations and add some other stuff. As
before, my notations are
in the instructions below as well as some pictures with references.

PARTS LIST

PART NO.----QUANTITY---- DESCRIPTION

69464..........1.........Bumper, H2

69347..........1.........Closure Shield, RH

69348..........1.........Closure Shield, LH

69609..........1.........Mounting Bracket, Outer

69196..........1.........Mounting Bracket, Inner

69119..........1.........Tow Loop Bracket, RH

69120..........1.........Tow Loop Bracket, LH

69121..........1.........License Bracket

TORQUE SPECIFICATIONS

BOLT SIZE TORQUE

3/8 inch 30 lb. ft. (40.7 N-m)

7/16 inch 50 lb. ft. (67.8 N-m)

½ inch 75 lb. ft. (101.7 N-m)

12mm 58 lb. ft. (78.7 N-m)

1. Open hood and remove light sockets from fog lights
(they are referring to the Daytime Running Lights, you should be able to do all
of this without opening your hood). Squeeze and push out the metal clips
that retain the lower center grille piece (A)
(you really don't have to do this, just pull on it and it will pop off).
Close hood to actually remove this grille. (Do not remove the main chrome grille (B)).

2. Pry up and remove the two plastic hole plugs (C)
from the top of the bumper plastic (be careful with these
as you will put them back and you can easily tear the edge getting them off).
These give access to the top two bumper bolts. Remove these two upper bolts and
the two lower bolts (these bolts all take 18mm socket)
at the bottom edge of the bumper (D).
Remove the bumper assembly.


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3. Remove the two tow loops and also the receiver bracket (E)
from the center of the front cross member (all of these
take 18mm socket).


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4. Install the RH (F) and LH (G)
Frame Extensions. The RH piece has the welded-on control box bracket as shown in
Photo 1. Use 1/2 x 1-1/2 bolts (these require 3/4 inch
socket), lock washers and nuts. Install the factory tow loops onto the Frame
Extensions with the factory bolts at the rear holes only 
(I would suggest leaving the tow loops off completely here. In step 11
you can easily re-mount the tow loops completely but if you leave them in
place it makes it difficult to tighten the two bolts attaching the frame
extension tabs to the mounting plate). Leave out the front bolts
and leave the rear bolts loose at this time, allowing the tow loop to pivot downward.
(See step 16 (I think they meant 11)).

5. Match drill (7/16”) the vehicle frame horns to the holes (H)
provided in the upper tabs of the Frame extensions. Install 7/16 x 1-1/4 bolts (these
take 5/8 inch socket for the bolt heads and a 11/16 inch socket for the nuts

),
lock washers and nuts. Tighten all bolts (except tow loops) securely at this point.


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1. Install the inner section (I) of
the Winch Mounting Bracket to the cross member. Tighten the 4 factory bolts evenly
while making sure both angled surfaces are lying down flush at the same time. Tighten
securely.

2. Install the outer front section (J)
of the Winch Mounting Bracket as shown in Photo 2. Tighten only finger tight until
directed later.


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3. Install the fairlead bolts (K) (7/16 x 1-1/4) from the inside out, prior to installing
winch.

4. Install the control box (L) onto the RH Frame Extension bracket with the wiring to
the rear near the vehicle body (look at the photo below,
if your bolts are mounted to the bottom of the control box like this then it
is backwards and cannot mount with the wiring to the rear). See Photo 3. Install the black ground (-) cable
(this big black cable will already be attached to the
bottom of the winch)
and the ground lead from the control box (this is the
small black wire with the loop connector on the end) to the bottom of the winch motor before
dropping the winch into place. Now install the winch and tighten securely.


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5. Make the electrical connections to the winch motor terminals as described in
the winch installation instructions. Route the long power cables and the remote
control harness along the back edge of the inner Winch Mounting Bracket near the
brake line. Near the steering gear, route the long power cables up to the battery
vicinity. Tie wrap the cables and harness to the brake line and be sure that they
are secured away from sharp edges and moving parts.

6. The Warn Bumper requires some sub assembly work before it is ready for installation.
First, go to the original factory bumper and remove the upper plastic section
(M) with
lights from the main metal section. Install the plastic section onto the Warn Bumper
with the original factory fasteners (these take 13mm socket).
Refer to Photo 4 showing the inside view of the bumper. Install the metal Closure
Shields (N) as shown, sharing two factory bolts on each side.


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7. Install the Remote Control Socket onto the top of the bumper using the holes
provided. The lanyard on the cap should be oriented toward the outboard side so
that the slot is visible to the front when the cap is removed.

8. Install the Warn Bumper assembly onto the vehicle. Secure it to the frame using
the original bolts (all of these
take 18mm socket) and tighten securely.

9. Install the Fairlead over the protruding bolts. If a front license plate is needed,
install the bracket provided between the fairlead and the bumper, and then tighten
the fairlead bolts securely.

10. Now, from underneath the vehicle, tighten the five nuts on the round head bolts (these require 3/4 inch
socket)
that connect the two mounting plate sections together.

11. Working through the tow loop area with the tow loops pivoted down for access,
tighten the frame extension tab to mounting plate nuts (these require
11/16 inch
wrench) securely. Now install the
front tow loop fasteners and tighten all six securely.

12. Connect the remote control harness leads together, matching the color-coded
wires.

13. Reconnect the fog light sockets. Reinstall the hole plugs and the small plastic
grille.

14. Make the electrical power lead connections to the side terminal battery using
the special brass fasteners provided. Push out the original factory fastener from
the each battery cable and replace with the brass fastener. The winch lead is then
connected using the brass hex bolt. The other bolts and nuts furnished are not used
in this application.

15. Install hook onto the winch wire rope. Refer to the winch installation instructions
and test the clutch operation and the “power in” and “power out” functions.

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PARAGON · #2 09-27-2004, 02:50 PM