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©2019 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 

105968A0

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 7

Figure 8

Figure 9

6.  Remove sensors from sensor carriages.

a.  Spread the top and bottom tabs of the sensor  

carriage outward.

b.  From the outside of the bumper, push sensor 

towards the inside of the bumper.  

NOTICE

 Be 

sure to mark the location and orientation of each 

sensor plug.  

 

TIP:  Numbering each sensor with tape and marking the top 

with a paint pen works well.

7.  Remove the carriages from stock bumper.
 

a.  Squeeze in the two tabs on the side of the carriages  

 

and push each carriage out the front of the bumper.

8.  Release the plastic clips holding the wire harness in place 

and remove completely.

9.  From the front of the bumper, carefully insert each 

sensor carriage into the correct mounting hole and 

snap into place.  

NOTE:  Be sure sensors match the 

orientation of the stock bumper. 

Tab

Tab

Tab

Tab

Figure 10

Summary of Contents for 103638

Page 1: ...your winch and its operations Never work under vehicle before properly securing vehicle Always use appropriate and adequate care in lifting components into place Never work under vehicle before properly securing vehicle Always use appropriate and adequate care in lifting components into place Never use a jack to support the vehicle Always use jack stands in pairs to support the vehicle Always use ...

Page 2: ...ve these instructions could lead to minor or moderate injury Part edges may be sharp Always use proper posture lifting technique or get lifting assistance while handling and installing product Read installation and operating instructions thoroughly This product may interfere with driver assist systems such as adaptive cruise control and parking as sist systems that have sensors or cameras installe...

Page 3: ...L I S T T O R Q U E S P E C I F I C A T I O N S Item PN Description Qty A1 102453 BUMPER 1 A2 103691 SPACER 2 A3 103636 CROSSMEMBER WELDMENT 1 A4 95648 RH MOUNTING BRACKET 1 A5 95643 LH MOUNTING BRACKET 1 A6 100903 LH LIGHT BRACKET 1 A7 100904 RH LIGHT BRACKET 1 A8 94889 LH LIGHT PORT 1 A9 94888 RH LIGHT PORT 1 Item PN Description Qty B1 100661 9 16 LOCKING PLUG 6 B2 102248 1 3 32 PLUG 6 B3 93106 ...

Page 4: ...move fender liner Using an 8mm socket remove the three screws in fender well Repeat for other side b Remove the two remaining lower screws to release fender liner Repeat for other side c Slide fender line down and out 2 If equipped unplug the wiring harness located in the front left corner of the bumper Figure 1 Fender well bolt Figure 2 Figure 3 ...

Page 5: ... bumper Repeat for other side CAUTION Always use assistance when moving or lifting heavy parts 4 Carefully remove bumper and set on a clean and stable surface 5 If equipped remove the active air dam a Unplug the motor and remove the four retaining nuts with a 12mm socket see Figure 5 and 6 NOTE The air dam will not be reinstalled with the new bumper Remove nuts Unplug Remove nuts Figure 4 Figure 5...

Page 6: ...k the location and orientation of each sensor plug TIP Numbering each sensor with tape and marking the top with a paint pen works well 7 Remove the carriages from stock bumper a Squeeze in the two tabs on the side of the carriages and push each carriage out the front of the bumper 8 Release the plastic clips holding the wire harness in place and remove completely 9 From the front of the bumper car...

Page 7: ...a 19mm socket and wrench loosely mount the crossmember to the mounting brackets and bumper by installing 8 bolts B5 with 8 washers B3 into the mounting hole and securing with 8 washers B3 and nuts B4 CAUTION Always use assistance when moving or lifting heavy parts NOTE For the next step we recommend getting assistance from one or two more people 15 With assistance line up the bumper crossmember as...

Page 8: ...oded view on page 3 24 The remaining hardware B1 and B2 are to used to install license plate to new bumper 25 Tighten ALL hardware now refer to torque specifications on page 3 26 If not installing a Baja Bar insert plugs B1 into the holes in the top of the bumper CARELESS INSTALLATION AND OPERATION CAN RESULT IN SERIOUS INJURY OR EQUIPMENT DAMAGE READ AND UNDER STAND ALL SAFETY PRECAUTIONS AND OPE...

Page 9: ...PRODUCT M A I N T E N A N C E C A R E 1 Inspect all parts on the winch winch mount and related hardware prior to each use Replace all 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 us...

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