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WARN INDUSTRIES

 

PAGE 1

 

73465 A2 

 

 

 

 

 

 

 

 

 

 
 
 
 
 
 
 
 
 
 
 
 
 
 

 
 

 
 
 

 

NOTES  

This bumper is not compatible with the factory optional front skid plate.  Optional skid plate must be 
removed for bumper installation. 

 

 

 
 
 

Your safety, and the safety of others, is very important. To help you make informed decisions about safety, we have provided 
installation and operating instructions and other information on labels and in this guide. This information alerts you to potential 
hazards that could hurt you or others. It is not possible to warn you about all potential hazards associated with this product, you 
must use your own good judgment.

  

CARELESS INSTALLATION AND OPERATION CAN RESULT IN SERIOUS INJURY OR EQUIPMENT DAMAGE. 
READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND OPERATING INSTRUCTIONS BEFORE 
INSTALLING AND OPERATING THIS PRODUCT. 

This guide identifies potential hazards and has important safety messages that help you and others avoid personal injury or 
death. 

WARNING

 and 

CAUTION

 are signal words that identify the level of hazard. These signal words mean:  

 WARNING signals a hazard that could cause serious injury or death, if you do not follow recommendations. 

 CAUTION signals a hazard that may cause minor to moderate injury, if you do not follow recommendations.

  

This guide uses 

NOTICE

 to call attention to important mechanical information, and 

Note:

 to emphasize general information 

worthy of special attention. 

Notice

 

Equipment Damage

 

 

Always 

refer to the 

I

nstallation and Specification Guide, supplied in the winch kit, for all wiring 

schematics and specific details on how to wire this WARN product to your vehicle. 

Read installation and operating instructions thoroughly.

 

  WARNING

 

 

INJURY HAZARD 

Failure to observe these instructions could lead to severe injury or death.

 

 

 

Always 

Read the Winch Operator’s Manual and all warning labels before operating.

 

 

Always 

use extreme caution when drilling on any vehicle. Make sure that all fuel lines, brake lines, electrical wires, and other objects are 

not punctured or damaged when/if drilling on the vehicle. Thoroughly inspect the area to be drilled (on both sides of material) prior to 
drilling, and relocate any objects that may be damaged. Failure to inspect the area to be drilled may result in vehicle damage, electrical 
shock, fire or personal injury. 

 

Always 

wear safety glasses when installing this kit. A drilling operation will cause flying metal chips. Flying chips can cause eye injury. 

 

Always 

use extreme caution when cutting and trimming during fitting. 

 

Always 

remove jewelry and wear eye protection.

 

 

Never 

lean over battery while making connections.

 

 

Never route electrical cables: 

Across any sharp edges. 

Through or near moving parts. 

Near parts that become hot. 

 

Always

 insulate and protect all exposed wiring and electrical terminals. 

 

Always

 install terminal boots as directed in installation instructions. 

 

Always 

use appropriate and adequate care in lifting components into place.

 

 

 

Always 

insure components will remain secure during installation and operation. 

 

Always 

tighten all nuts and bolts securely, per the installation instructions..

 

 

Always 

replace all worn or damaged parts before operating.

 

 

Never 

operate this WARN product with damaged or missing parts. 

INSTALLATION INSTRUCTIONS

HEAVY DUTY WINCH BUMPER 

Part Number: 73040 

Application: 2007 TOYOTA FJ CRUISER 

Summary of Contents for 73040

Page 1: ...w to wire this WARN product to your vehicle Read installation and operating instructions thoroughly WARNING INJURY HAZARD Failure to observe these instructions could lead to severe injury or death Always Read the Winch Operator s Manual and all warning labels before operating Always use extreme caution when drilling on any vehicle Make sure that all fuel lines brake lines electrical wires and othe...

Page 2: ...627 Light Bracket LH 1 73775 Light Bracket RH 1 73774 License Plate Bracket 2 73469 Spacer Tube 2 76198 II TOOLS REQUIRED 10mm socket 11 16 socket and end wrenches 12mm socket 3 4 socket and end wrenches 14mm socket Flat blade screw driver 17mm socket 1 4 and 1 2 drill 7 16 socket and end wrenches Safety glasses 5 8 socket and end wrenches 12 x 40mm Bolt Lock Washer Flat Washer ...

Page 3: ...t 101 7 N m IV INSTALLATION 1 Remove the screws from the rear corners of the bumper two in each side Figure 2 Figure 2 Bumper mounting screws left side 2 Remove the eight screws along the bottom of the bumper Figure 3 Figure 3 Lower bumper mounting screws Remove 2 screws in rear of bumper Remove 8 screws in bottom of bumper 4 per side ...

Page 4: ...ners 4 Remove the two plastic fasteners from the top of the grille Retain the hardware for use later Carefully pry the center pins up before removing the fasteners Figure 5 Figure 5 Left grille fastener removal 5 Pull the grille free of the retaining clips with a sharp pull Remove 2 screws Remove 2 plastic fasteners 1each side Lift center pin then pry fastener out ...

Page 5: ...port Figure 6 Figure 6 Bumper fasteners 7 Pull the bumper corners free by pulling the ends rearward and out The top of the bumper is snapped into plastic clips just below the fender corners in front of the flares Pull the bumper free Figure 7 Figure 7 Left bumper end removal Remove 5 plastic fasteners 2 behind bumper not shown ...

Page 6: ...lace and remove the blocks Figure 8 Figure 8 LH bumper mounting block 9 Remove the three screws and remove the upper bumper support Figure 9 Figure 9 Upper bumper support Remove 2 screws and remove plastic block Remove 3 screws Do not remove the nuts on top Bumper mounting block Upper bumper support ...

Page 7: ...side shown 11 Remove the four screws and remove the skid pan Retain the hardware for reinstallation of the skid pan Figure 11 Figure 11 Skid pan 12 Remove the molded plastic inner fender extensions by clipping or drilling out the rivets holding them to the bottom of the inner fenders Figure 12 Remove 4 fasteners to remove skid pan Remove 4 flange nuts per side Bumper beam ...

Page 8: ...as a centering tool Repeat for opposite side Figure 13 Figure 13 Outside left frame rail 13 Hold a Frame Bracket in position and insert a 12mm bolt with 1 2 lock washer and flat washer through the bottom hole in the Bracket and into the threaded hole in the frame Do not tighten yet Figure 14 Drill hole through center of existing hole into inner frame wall Clip or drill rivets to remove fender exte...

Page 9: ...ter hole in the bottom of the right end of the front cross member Enlarge the hole in the top to 1 2 Note Do not drill into the radiator Figure 15 17 Locate the left outer hole in the bottom of the front cross member This is threaded and some vehicles have a transmission cooler line bracket bolted into it Remove the bolt if equipped and carefully enlarge 12mm bolt lock washer and flat washer 1 2 x...

Page 10: ...the bumper onto the eight bumper beam studs The Frame Brackets should be outboard of the Bumper Gusset Plates Install the original 12mm flange nuts Do not tighten yet 19 Hold the RH Cross Member Bracket in place against the cross member and insert a 1 2 x 2 1 4 bolt and flat washer through the Bracket and cross member Install a 1 2 flat washer lock washer and nut Do not tighten yet Figure 17 Figur...

Page 11: ...ss Member Bracket 22 Insert a 7 16 x 1 1 2 bolt with flat washer through each of 3 slots in the Bumper Gusset Plate into the Frame Brackets Install a 7 16 flat washer lock washer and nut on each Do not tighten yet 23 Level the bumper and tighten the eight flange nuts 24 Tighten the 1 2 x 4 frame bolts then the 12mm Lower Frame Bracket bolt 25 Tighten the Bumper Gusset Plate hardware 26 Finally tig...

Page 12: ...ashers lock washers and nuts The shape of some winches may prevent the use of these brackets Figure 21 Figure 20 RH Light Bracket installed Install the License Plate L Brackets using the 1 4 hardware The brackets can be installed from the back of the bumper Figure 22 Drill a 1 4 hole in the inner fender and zip tie around the body mount stud 2 7 16 bolt lock washer hex nut ...

Page 13: ...ll 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 freely WARNING READ THE VEHICLE S OPERATOR MANUAL WINCH OPERATOR MANUAL AND ALL WARNING LABELS PRIOR TO OPERATION WINCH WARNING FAILURE TO SECURELY TIGHTEN ALL BOLTS ON THE BUMPER WINCH AND FAIRLEAD CAN RESULT IN PRODUCT FAILURE WHICH MAY RESULT IN...

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