Warn 103209 Installation Instructions Manual Download Page 7 | Manualshive

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Warn 103209 Installation Instructions Manual Download Page 7

©2017 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.

7

105714A0

Figure 13

14. Reinstall the plastic fender liners using original hardware.

15. Mount the fairlead to the semi hidden weldment (3),

according to your winch mounting instructions.

16. Mount the winch to the semi hidden weldment according to

your winch mounting instructions

WARNING

Always use assistance when moving or lifting heavy parts.

17. With assistance, place bumper in position on vehicle.

Do not

install nuts yet.

18. Before installing the semi hidden weldment/winch assembly,

route the winch power cables through the cutout in the

bumper and in front of the radiator.

Figure 15

Figure 16

Winch

Fairlead

Figure 14

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Summary of Contents for 103209

Page 1: ...electricalterminals Alwaysinstallterminalbootsasdirectedininstallationinstructions Alwaysuseappropriateandadequatecareinliftingcomponentsintoplace Alwaysinsurecomponentswillremainsecureduringinstallationandoperation Alwaystightenallnutsandboltssecurely pertheinstallationinstructions Alwaysperformregularinspectionsandmaintenanceontheplowmechanism fasteners cableandrelatedhardware Alwaysreplaceallwo...

Page 2: ...cifications page 2 Parts List page 3 Installation page 4 8 Maintenance Care page 8 T O O L S R E Q U I R E D Standard wrenches Standard sockets Reciprocal saw or other cutting tool B E F O R E Y O U B E G I N N O T I C E This product may interfere with driver assist systems such as adaptive cruise control and parking assist systems that have sensors or cameras installed in the bumpers or front gri...

Page 3: ... Inc 3 105714A0 P A R T S L I S T ITEM PART NO DESCRIPTION QTY 1 103206 LH BUMPER BRACKET 1 2 103195 RH BUMPER BRACKET 1 3 102846 SEMI HIDDEN WELDMNT 1 ITEM PART NO DESCRIPTION QTY 4 83125 M6 X 1 0 NUT 2 5 64108 M6 1 0 x 25 BOLT 2 6 102248 BLACK PLASTIC PLUG not shown 2 2 1 3 4 5 ...

Page 4: ...m socket remove grille by removing the four front center screws as well as the two outer push pins 2 Remove one plastic clip from fender liner both sides 3 Using a 17mm socket remove the two bolts securing the tow hook each side Remove tow hook and set aside Save tow hook and bolts for reuse Figure 1 Figure 2 Figure 3 Plastic clips 10mm bolts Plastic clip ...

Page 5: ...upcoming installation 5 From underneath the bumper use a 14mm socket to remove the four nuts each side holding the bumper structure to the frame rails Save nuts for reuse 6 If equipped disconnect harness from rear of fog lamps and disconnect park sensor harness both sides WARNING Always use assistance when moving or lifting heavy parts 6 Remove and set aside bumper Figure 5 Figure 6 Figure 4 ...

Page 6: ...using the six reinforcement bar nuts 12 From the outside of the bumper use a reciprocating saw or similar tool to carefully cut out the center plastic following styling lines Tip Mask cut lines to prevent unnecessary damage NOTE Relocating the control pack can be done to avoid next step For winches with top mounted control pack only 13 From the inside of the bumper carefully cut a 10 x 2 inch sect...

Page 7: ...ing instructions 16 Mount the winch to the semi hidden weldment according to your winch mounting instructions WARNING Always use assistance when moving or lifting heavy parts 17 With assistance place bumper in position on vehicle Do not install nuts yet 18 Before installing the semi hidden weldment winch assembly route the winch power cables through the cutout in the bumper and in front of the rad...

Page 8: ...commend using a floor jack to help with this 24 Now that all the hardware is installed a Check to make sure that there isn t to much space between the frame brackets and the bumper b Confirm bumper is centered and aligned vertically and horizontally c Once satisfied with alignment torque all hardware to suggested values on page 2 NOTE Always make adjustments with assistance 25 Installation is now ...

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