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©2016 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.

 2 

101403A0

  

 

C A U T I O N

MOVING PARTS ENTANGLEMENT HAZARD

Failure to observe these instructions could lead to minor or moderate injury

• 

Always

 take time to fully read and understand the installation and Operations Guide included with this product.

• 

Never

 operate this product if you are under 16 years of age.

• 

Never

 operate this product when under the influence of drugs, alcohol or medications.

Read installation and operating instructions thoroughly.

T A B L E   O F   C O N T E N T S

Tools Required .............................................................................................................................page 2

Torque Specifications ................................................................................................................page 2

Parts List.........................................................................................................................................page 3

Installation ................................................................................................................................page 4-7

Maintenance/Care ......................................................................................................................page 7

T O O L S   R E Q U I R E D

-  Standard wrenches

-  Standard sockets

T O R Q U E   S P E C I F I C A T I O N S

Please use the recommended torque specifications when assembling this product unless otherwise specified in the instructions.

FASTENER SIZE 

FASTENER TORQUE 

FASTENER SIZE 

FASTENER TORQUE 

lb-ft 

(N.m) 

lb-ft 

(N.m) 

1/4" 

8

(11)

M4

(2)

3

5/16" 

17

(23)

M5

(4.5)

6

3/8" 

30

(40)

M6

(7.5)

10

7/16”

48

(66)

M8

(18)

25

1/2" 

74

(100)

M10

(37)

50

9/16”

106

(144)

5/8" 

148

(200)

3/4”

269

(364)

N O T I C E

EQUIPMENT DAMAGE

• 

Never

 tow vehicle by attaching a tow bar to the eyelets on the bumper.  

• 

Never

 attach tow bars directly to the bumper.  Damage to bumper may occur.  WARN bumpers are not designed to be used for flat towing.  Consult with the manufacturer of your tow bar system for the proper vehicle tow 

bar brackets..

Read installation and operating instructions thoroughly.

Summary of Contents for 101394

Page 1: ...andelectricalterminals Alwaysinstallterminalbootsasdirectedininstallationinstructions Alwaysuseappropriateandadequatecareinliftingcomponentsintoplace Alwaysinsurecomponentswillremainsecureduringinstallationandoperation Alwaystightenallnutsandboltssecurely pertheinstallationinstructions Alwaysperformregularinspectionsandmaintenanceontheplowmechanism fasteners cableandrelatedhardware Alwaysreplaceal...

Page 2: ...ion page 4 7 Maintenance Care page 7 T O O L S R E Q U I R E D Standard wrenches Standard sockets T O R Q U E S P E C I F I C A T I O N S Please use the recommended torque specifications when assembling this product unless otherwise specified in the instructions FASTENERSIZE FASTENERTORQUE FASTENERSIZE FASTENERTORQUE lb ft N m lb ft N m 1 4 8 11 M4 2 3 5 16 17 23 M5 4 5 6 3 8 30 40 M6 7 5 10 7 16 ...

Page 3: ...3 101403A0 P A R T S L I S T ID No Item No Description Qty A1 101398 FAIRLEAD ASSEMBLY 1 A2 101395 WINCH MOUNT ASSEMBLY 1 ID No Item No Description Qty B1 83349 M6 FLAT WASHER 2 B2 60595 M6 LOCKING NUT 2 B3 22491 M8 LOCKING NUT 4 B4 1324 5 16 FLAT WASHER 8 B5 22508 M8 HEX BOLT 4 A2 A1 ...

Page 4: ... 101403A0 I N S T A L L A T I O N I N S T R U C T I O N S 1 Remove the screws that hold the front plastic to the bumper structure 2 Remove the fastener to the bottom of the radiator bracket on both sides 3 Remove the nuts holding the lower A Arms Figure 1 Figure 2 Figure 3 Remove Remove ...

Page 5: ...Arms Use care in not damaging radiator while removal 6 The front of the Maverick is now ready to install the rear weldment of the winch mount 7 Place the rear winch mount weldment over the four A Arm mounting bolts shown in previous picture Use the same orientation as shown in picture I N S T A L L A T I O N I N S T R U C T I O N S Figure 5 Figure 6 Figure 4 A Arm Nut Bumper Structure Fairlead Wel...

Page 6: ...lied in your winch kit 9 Before you install winch review Figure 8 The illustration shows correct winch orientation Notice the winch clutch handle should be on the passenger side of the vehicle The winch rope winds off the top of the winch drum and through the fairlead opening 10 Slide winch into position Install using hardware and instructions found in your winch kit Figure 8 Figure 9 Figure 7 Att...

Page 7: ... hardware that appears rusted or deformed 2 Inspect all nuts and bolts on the winch winch mount and related hardware prior to each use Tighten all nuts that appear to be loose Stripped fractured or bent bolts or nuts need to be replaced 3 Check all cables prior to use Replace cables that look worn or frayed 4 Check all moving or rotating parts Remove debris that may inhibit the part from moving fr...

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