Warn 96640 Installation Instructions Manual Download Page 1

©2015 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.

 1 

96616A1

WARN INDUSTRIES, INC.

 12900 S.E. Capps Road,

Clackamas, OR USA 97015-8903, 1-503-722-1200, FAX: 1-503-722-3000

Customer Service:

 1-800-543-9276

Dealer Locator Service:

 1-800-910-1122

International Fax:

 1-503-722-3005

INSTALLATION INSTRUCTIONS

ASCENT REAR BUMPER

Part Number: 96640

Application:  Dodge Ram 1500, 2500, 3500 2015+

G E N E R A L   S A F E T Y   P R E C A U T I O N S

  

 

W A R N I N G

IMPACT AND MOVING PARTS ENTANGLEMENT HAZARD

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

•  Always 

take time to fully read the Instructions and/or Operations Guide, and/or Basic Guide to Winching Techniques, in order to understand your winch and its operations.

•  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:

  o  Across any sharp edges.
  o  Through or near moving parts.
  o  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

 perform regular inspections and maintenance on the plow mechanism, fasteners, cable and related hardware.

•  Always

 replace all worn or damaged parts before operating.

•  Never

 operate this WARN product with damaged or missing parts.

Read installation and operating instructions thoroughly.

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.

Summary of Contents for 96640

Page 1: ...ngandelectricalterminals Alwaysinstallterminalbootsasdirectedininstallationinstructions Alwaysuseappropriateandadequatecareinliftingcomponentsintoplace Alwaysinsurecomponentswillremainsecureduringinst...

Page 2: ...page 2 Torque Specifications page 2 Parts List page 3 Installation page 4 8 Maintenance Care page 8 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...

Page 3: ...IGHT BEZELS 2 Ram 1500 2500 AND 3500 ITEM PN DESCRIPTION QTY B1 6818 HEX HEAD BOLT 1 2 13 12 B2 9213 1 2 FLAT WASHER 24 B3 29060 1 2 LOCK NUT 12 B4 73665 U CLIP NUT 24 B5 91541 10 24 STAINLESS BOLT 24...

Page 4: ...Industries Inc 4 96616A1 I N S T A L L A T I O N I N S T R U C T I O N S 1 Remove license plate 2 Disconnect trailer wire harness located under vehicle between the spare tire and rear bumper 3 From un...

Page 5: ...5 Remove the outer bumper bracket bolts both sides 6 Remove the two bolts from the center of the bumper where license plate was 7 With assistance remove bumper and set aside carefully I N S T A L L A...

Page 6: ...with vehicle rear sensors remove now NOTE Take care when removing as you will reinstall in new bumper in same orientation See Figures 7 8 and 9 NOTE The sensor unclips from the sensor retainer then th...

Page 7: ...s downward Once the new bumper is on you can adjust the angle and retighten the clamps 12 Install the left and right hand bumper mounting brackets Do not tighten at this time See Figures 11 and 12 NOT...

Page 8: ...it in their specific hole 15 Install trailer hitch receptacle by pushing firmly into its designated hole in new bumper 16 Install four u clip nuts B4 to license lamp mounting plate A2 Refer to page 3...

Page 9: ...or rotating parts Remove debris that may inhibit the part from moving freely 18 Install license lamp mounting plate assembly to bumper using four stainless bolts B5 NOTE The license lamp will be sandw...

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