Warn 96550 Installation Instructions Manual Download Page 3

Page: 3 / 14

96551A2

P A R T S L I S T

ITEM PART NO. DESCRIPTION

QTY

96552

BUMPER WELDMENT

96285

LIGHT BEZEL

ITEM PART NO. DESCRIPTION

QTY

91541

SOCKET HEAD SCREW 10-24

96329

U-CLIP NUTS

90846

PLASTIC PLUG

6818

HEX HEAD BOLT

9213

FLAT WASHER

29060

LOCK NUT

8160

3/8-16 X 1.5 HEX HEAD BOLT

11524

3/8 FLAT WASHERS

6779

3/8 LOCK NUTS

B10

13231

BLACK ZIP TIES

B11

69427

FLAT WASHER

B12

98180

NUT ASSEMBLY

B12

Summary of Contents for 96550

Page 1: ...iringandelectricalterminals Alwaysinstallterminalbootsasdirectedininstallationinstructions Alwaysuseappropriateandadequatecareinliftingcomponentsintoplace Alwaysinsurecomponentswillremainsecureduringinstallationandoperation Alwaystightenallnutsandboltssecurely pertheinstallationinstructions Alwaysperformregularinspectionsandmaintenanceontheplowmechanism fasteners cableandrelatedhardware Alwaysrepl...

Page 2: ... Removal of the OEM bumper for the 1500 page 4 6 Removal of the OEM bumper for the 2500 and 3500 page 7 9 Installation page 10 14 Maintenance Care page 14 T O O L S R E Q U I R E D Standard wrenches Standard sockets 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 in...

Page 3: ...2 96285 LIGHT BEZEL 2 ITEM PART NO DESCRIPTION QTY B1 91541 SOCKET HEAD SCREW 10 24 18 B2 96329 U CLIP NUTS 18 B3 90846 PLASTIC PLUG 4 B4 6818 HEX HEAD BOLT 4 B5 9213 FLAT WASHER 8 B6 29060 LOCK NUT 4 B7 8160 3 8 16 X 1 5 HEX HEAD BOLT 2 B8 11524 3 8 FLAT WASHERS 4 B9 6779 3 8 LOCK NUTS 2 B10 13231 BLACK ZIP TIES 12 B11 69427 FLAT WASHER 2 B12 98180 NUT ASSEMBLY 2 B12 ...

Page 4: ...ng steps are for the removal of the OEM bumper for the 1500 1 Remove rear license plate 2 From underneath the rear bumper unplug the trailer connector wire harnesses 3 Unplug license plate light wire harness and back up sensors if equipped NOTICE Be careful when removing sensors and sensor retainer from bumper as to not damage Figure 1 Figure 2 Figure 3 ...

Page 5: ...if you have the right size blocks it may not be necessary 5 Remove the two bolts one on each side of the license plate opening that attach the center of the bumper to the hitch NOTE You may remove the trailer harness receptacle at this time by depressing the two metal clips or wait until bumper is removed 6 Remove the two frame nuts and the one frame bolt each side Figure 6 Figure 6 Figure 4 Remov...

Page 6: ...r bolts one on each side of truck You will need an extension to reach the bolt 9 Next you will loosen the box s front bolts located about two feet toward the front of the vehicle from the rear bolt just removed There will be a large hole that you can insert a socket and extension through to loosen the bolt one on each side 10 Repeat steps for other side 11 With assistance carefully remove bumper 1...

Page 7: ...2 From underneath the rear bumper unplug the trailer connector wire harnesses license plate and sensor wiring harness if applicable NOTICE Be careful when removing sensors and sensor retainer from bumper as to not damage 4 Remove spare tire rod lock NOTE It might be easier if you remove the spare tire at this time in order to lift the bed of the pickup however if you have the right size blocks it ...

Page 8: ...ing a socket remove three bolts attaching OEM bumper to frame 7 Remove the bumper bracket bolt Retain bolt as you will be reinstalling later using the nut assembly supplied in this kit NOTE To be able to remove the bumper with the frame brackets you will need to lift the back of the pickup box bed 9 Un bolt the box s rear bolts You will need an extension to reach the bolt 10 Repeat steps for other...

Page 9: ...x bed and use floor jack with blocks to slightly lift the box approximately 1 2 inch 15 With assistance carefully remove bumper 16 Using the nut assembly B2 reinstall the bumper bracket bolt which was previously removed in step 7 Go to page 10 for your WARN Bumper installation instructions Remove C A U T I O N Alwaysuseassistancewhenmovingorliftingheavyparts N O T I C E Onlyliftthebedapproximately...

Page 10: ...e is equipped with vehicle rear sensors remove now NOTE The sensor unclips from the sensor retainer then the retainer unclips from the bumper See Figures 9 and 10 NOTICE Be careful when removing sensors and sensor retainer from bumper as to not damage 4 Repeat steps for other side 5 Carefully remove OEM spare tire access housing NOTE Using a pick bend each prong back and out of way Take care bendi...

Page 11: ...all screwdrivers pry the inner ring loose from the outer ring by unsnapping the four detents holding in place 7 Remove outer ring from stock bumper and insert in new bumper 8 Carefully bend prongs back in place on the inner ring and reinstall in new bumper See Figure 6 and 7 Figure 4 Figure 5 Figure 6 Figure 7 ...

Page 12: ...s ofWarn Industries Inc 12 96551A2 9 Insert the OEM spare tire access housing to rings in new bumper 10 Insert trailer harness receptacle into new bumper 11 Insert one u clip nut B2 over lower tab on license plate lamp weldment u clip Figure 8 Figure 9 Figure 10 ...

Page 13: ...late lamp harness 15 Repeat steps for other side 16 If applicable install the stock sensor retainers into new bumper 17 From behind bumper route the sensor harness through frame bracket and insert in sensor retainer NOTE If your vehicle did not come equipped with rear sensors use the supplied plugs to cover sensor locations Screw License Plate Lamp Plug Figure 11 Sensor retainer Figure 12 Figure 1...

Page 14: ...d view on page 3 21 Install light bezels and secure using the stainless hardware provided in your kit 22 Installation is now complete Figure 14 Figure 15 Figure 16 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 har...

Search results

Summary of Contents for 96550

Reviews:

Related manuals for 96550

Brands by name

Popular brands

Warn 96550, Installation Instructions Manual

Search results

Summary of Contents for 96550

Reviews:

Related manuals for 96550

Brands by name

Popular brands