Warn 82459 Installation Instructions Manual Download Page 1

 

 

 

Instruction

 

Disclaimer

 

 

 
Dennis Kirk provides instructions to help our customers better understand how to install the 
products we sell. The instructions are exact copies of what the manufacturer includes with the 
product being sold. 
 
That means the quality and accuracy of the instructions is solely dependent on what the 
manufacturer produces. We do our best to make the text legible and the pictures viewable. 
However, the end result depends largely on the quality of instructions the manufacturer 
provides. 
 
Therefore, you will find that some instructions are not of the highest quality. Sometimes text is 
hard to read and pictures are not easy to see. At times you will find the overall look of the 
instructions to be less than professional. However, we feel it is better to provide what we have 
rather than provide nothing at all. 
 
To the best of our knowledge the instructions and application information contained in the 
instructions is accurate. However, Dennis Kirk assumes no liability related to any errors that 
may be contained in the copy of the manufacturer’s instructions we provide. Buyers are solely 
responsible to insure that product use is consistent with their application. 
 
If you have any questions please contact us at 

[email protected]

 or  

800-969-7501 so we can further assist you regarding additional product information or any other 
business related questions. 
 
Thank you for doing business with Dennis Kirk. 

Summary of Contents for 82459

Page 1: ...and pictures are not easy to see At times you will find the overall look of the instructions to be less than professional However we feel it is better to provide what we have rather than provide nothing at all To the best of our knowledge the instructions and application information contained in the instructions is accurate However Dennis Kirk assumes no liability related to any errors that may be...

Page 2: ...njury if you do not follow recommendations This guide uses INOT CElto call attention to important mechanical information and Note to emphasize general information worthy of special attention WARNING INJURY HAZARD Failure to observe these instructions could lead to severe injury or death o Always remove jewelry and wear eye protection o Never lean over battery while making connections o Never route...

Page 3: ...ment Damage D Always refer to the Installation 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 I PARTS LIST ITEM DESCRIPTION PIN OTY 1 2 3 4 5 6 7 8 9 RETAINING RING 6 SCREW CLUTCH CAP WAVE SPRING THRUST WASHER THRUST ROLLER BEARING BRAKE DISK AS...

Page 4: ...from the Clutch Dial 4 Use external retaining ring pliers to expand re taining ring Figure 3 Expand retaining ring only enough to allow it to be lifted from center hub Remove retaining ring and then lift Clutch Dial from Clutch Bar and Clutch Cap 5 Turn the Clutch Bar so that the heads of the Clutch Pins are in the eyes of the bar key slots Figure 4 Lift the Clutch Bar vertically from the Clutch C...

Page 5: ... D ring kit 9 Place brake retaining plate in hex bore of gear housing Figure 8 10 Place Brake Disk Assembly over Drive Shaft and slide it down until disk surface is resting on Brake Retaining Plate Figure 9 11 Apply a small amount of high temperature grease to the back of Brake Disk Assembly if there is none on disk Figure 10 WARN INDUSTRIES PAGE 4 2009 Warn Industries Inc WARN and the WARN logo a...

Page 6: ... the next step 15 Align the new Clutch Cap with Clutch Pins Drive Shaft Brake Spring and fastening holes Place the new Clutch Cap on Gear housing making sure that Brake Spring is in spring bore Figures 14and 15 16 Install 6 Torx head fasteners with T15 Screw driver Tighten these fasteners in a cross pattern so that Clutch Cap is fastened down straight and on center Torque 6 fasteners to 16in lb 1 ...

Page 7: ...slots 18 Align bumps on Clutch Dial with matching fea tures on Clutch Bar Figure 17 Push the Clutch Dial down over Clutch Cap center hub Use re taining ring pliers to install retaining ring Check for proper installation by turning Clutch Dial to Freespool position Reinstall Clutch Dial if it does not move freely 19 Reinstall clutch handle 20 Follow winch and mounting kit instructions to re install...

Page 8: ... 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 freely PERFORM REGULAR I...

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