Warn 73040 Installation Instructions Manual Download Page 5

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WARN INDUSTRIES

PAGE 5

73465 A2

6. Remove five plastic fasteners from the top of the bumper. Two are behind the upper bumper support.

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)

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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