New Warn winch bumper system installation

PARAGON · #1 09-24-2004, 10:39 PM

I'm going to go ahead and start this thread on the installation since I have completed a good portion of it. So far it has been very easy and straightforward. I'll make some notations in the instructions below as well as point out a couple of things using pictures from the installation instructions.

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.

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).

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. Leave out the front bolts and leave the rear bolts loose at this time, allowing the tow loop to pivot downward. (See step 16).

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.

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.

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

4. Install the control box onto the RH Frame Extension bracket with the wiring to the rear near the vehicle body. See Photo 3. Install the black ground (-) cable and the ground lead from the control box to the bottom of the winch motor before dropping the winch into place. Now install the winch and tighten securely.

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 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 as shown, sharing two factory bolts on each side.

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 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 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 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.

PARAGON · #2 09-24-2004, 10:39 PM

I'm going to go ahead and start this thread on the installation since I have completed a good portion of it. So far it has been very easy and straightforward. I'll make some notations in the instructions below as well as point out a couple of things using pictures from the installation instructions.

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.

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).

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. Leave out the front bolts and leave the rear bolts loose at this time, allowing the tow loop to pivot downward. (See step 16).

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.

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.

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

4. Install the control box onto the RH Frame Extension bracket with the wiring to the rear near the vehicle body. See Photo 3. Install the black ground (-) cable and the ground lead from the control box to the bottom of the winch motor before dropping the winch into place. Now install the winch and tighten securely.

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 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 as shown, sharing two factory bolts on each side.

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 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 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 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.

PARAGON · #3 09-24-2004, 10:39 PM

I'm going to go ahead and start this thread on the installation since I have completed a good portion of it. So far it has been very easy and straightforward. I'll make some notations in the instructions below as well as point out a couple of things using pictures from the installation instructions.

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.

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).

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. Leave out the front bolts and leave the rear bolts loose at this time, allowing the tow loop to pivot downward. (See step 16).

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.

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.

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

4. Install the control box onto the RH Frame Extension bracket with the wiring to the rear near the vehicle body. See Photo 3. Install the black ground (-) cable and the ground lead from the control box to the bottom of the winch motor before dropping the winch into place. Now install the winch and tighten securely.

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 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 as shown, sharing two factory bolts on each side.

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 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 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 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.

PARAGON · #4 09-25-2004, 12:22 AM

PARAGON · #5 09-25-2004, 12:23 AM

PARAGON · #6 09-25-2004, 12:24 AM

Photo 1 from instructions

PARAGON · #7 09-25-2004, 12:24 AM

Photo 2 from instructions

timgco · #8 09-25-2004, 12:59 AM

You're killing me here. UPS just dropped off my winch. Sat. morning is when I'm jumping into this project. It looks fairly easy, excpet I suck at electrical stuff.
How long do you think to complete?

Have you had any issues so far?

PARAGON · #9 09-25-2004, 01:16 AM

<BLOCKQUOTE class="ip-ubbcode-quote">quote:<HR>Originally posted by timgco:
You're killing me here. UPS just dropped off my winch. Sat. morning is when I'm jumping into this project. It looks fairly easy, excpet I suck at electrical stuff.
How long do you think to complete?

Have you had any issues so far? <HR></BLOCKQUOTE>My winch came so late, I haven't done anything with that. I stopped at number 3 of the second section except that I put the upper plastic section onto the top of the new Warn bumper and had to re-mount my Cibie Tangos onto the Warn bumper also.

No issues so far except that they have bolts that require a 5/8" socket that mates to nuts that require a 11/16" socket, but I am picky about crap like that.

It really has been easy so far and the electrical looks to be idiot-proof. The wires are labeled properly and you wire directly to the battery.

This is really an easy one person job, I am just still slow these days due to the illness and got some help from a buddy today. But I betting that one person(healthy) can easily complete it in 3-4 hours at most.

I didn't have a new 7/16" drill bit and had to run to the hardware store because my old one was dull and the frame you drill through is pretty thick.

I am extremely pleased so far and expect to wrap it up fairly easily tomorrow and finish out my notations and what not.

timgco · #10 09-25-2004, 01:23 AM

check your PM.

Patriot · #11 09-25-2004, 10:16 AM

Para,

Thanks for the details in the 'structions...it will help us others out very much. Good luck with the winch.

Also, in the picture above, you didn't give your dog a part number? Did he come with the kit? I'm sure he was vital in helping you get that thing mounted.

Fever · #12 09-25-2004, 10:30 AM

Hey guys I heard there might be an issue with the pos battery cable length being too short and the control box mtg bolts are backwards from the picture. Let me know if I can help. I know Warn will take care of any short comings.
Paragon,Timgco I have pm,d my cell # if you run into any problems.

Patriot · #13 09-25-2004, 10:38 AM

Did you take off your Warn light bar and go to stock lights?

DRTYFN · #14 09-25-2004, 01:09 PM

Drilling??? YUCK!!!!!

Should have waited a little bit longer. 8 mounting points with NO drilling. Oh yeah, and a 12K winch.

PARAGON · #15 09-25-2004, 02:31 PM

<BLOCKQUOTE class="ip-ubbcode-quote">quote:<HR>Originally posted by Patriot:
Did you take off your Warn light bar and go to stock lights? <HR></BLOCKQUOTE>Nope, keeping the light bar on as well. The reason the two are listed as not compatible is because when you open the hood all of the way, the light bar will hit the top of the winch bumper. I simply plan on shortening the opening of the hood to keep this from happening. I'll post what I end up doing for this fix.

I haven't done anything else on it so far, I've had a medical day so far. I had an appointment with my neurologist at 7:30am and when I got back from that we took my 3 year old daughter to the doc because she was stung by 3 red wasps and one got her on the eyelid. Bad deal, she needs a good cut-man. I am going to watch a little football now and will finish the install this afternoon.

And Drty, drilling = good, because of where you are making the additional mounting points. I had to drill into the bumper anyway to mount my Cibie Tangos.

Hummie2 · #16 09-25-2004, 02:39 PM

How much does the new winch and bumper weigh? How about a before and after measurement to see how much the front end sets down after the additional weight is added. If the H2 loses another inch of ground clearance on the front thats not good.

Fever · #17 09-25-2004, 04:36 PM

Total weight bumper and winch is about 185#.

Patriot · #18 09-25-2004, 06:48 PM

<BLOCKQUOTE class="ip-ubbcode-quote">quote:<HR>Originally posted by PARAGON:
<BLOCKQUOTE class="ip-ubbcode-quote">quote:<HR>Originally posted by Patriot:
Did you take off your Warn light bar and go to stock lights? <HR></BLOCKQUOTE>Nope, keeping the light bar on as well. The reason the two are listed as not compatible is because when you open the hood all of the way, the light bar will hit the top of the winch bumper. I simply plan on shortening the opening of the hood to keep this from happening. I'll post what I end up doing for this fix.

<HR></BLOCKQUOTE>

The reaon I asked is because I didn't see it on the H2 in the pictures posted above???

PARAGON · #19 09-25-2004, 06:50 PM

<BLOCKQUOTE class="ip-ubbcode-quote">quote:<HR>Originally posted by Fever:
Hey guys I heard there might be an issue with the pos battery cable length being too short and the control box mtg bolts are backwards from the picture. Let me know if I can help. I know Warn will take care of any short comings.
Paragon,Timgco I have pm,d my cell # if you run into any problems. <HR></BLOCKQUOTE>I think these two might be tied together. The bolts are placed on the bottom of the control box in such a way that the wires HAVE to come out towards the front. The instructions says to mount the box so that the wires are facing rearward. If the wires face forward then it would shorten the cable length some.

I have not hooked to the battery yet but am about there. I took the control box apart and re-oriented the mounting bolts so that it would mount with the wires facing rearward as the instructions say. I'll try to explain this in more detail as I explain the rest of the install.

I have to tighten a few bolts and complete the wire hook-ups and then I will be done. Here are a couple of pics with it basically done.

PARAGON · #20 09-25-2004, 06:51 PM

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