Warn 96640 Installation Instructions Manual Download Page 2

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

 2 

96616A1

N O T I C E

EQUIPMENT DAMAGE

• 

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.

  

 

C A U T I O N

MOVING PARTS ENTANGLEMENT HAZARD

Failure to observe these instructions could lead to minor or moderate injury

• 

Always

 take time to fully read and understand the installation and Operations Guide included with this product.

• 

Never

 operate this product if you are under 16 years of age.

• 

Never

 operate this product when under the influence of drugs, alcohol or medications.

Read installation and operating instructions thoroughly.

T A B L E   O F   C O N T E N T S

Tools Required .............................................................................................................................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

This product may interfere with driver assist systems such as adaptive cruise control and parking assist systems that have sensors or cameras installed in 

the bumpers or front grill area.  If your vehicle is equipped with any of these systems or features, consult your vehicle owner’s manual before installing 

this product.  These systems may need to be disabled as a result of installing this product.

T O R Q U E   S P E C I F I C A T I O N S

Please use the recommended torque specifications when assembling this product unless otherwise specified in the instructions.

FASTENER SIZE 

FASTENER TORQUE 

FASTENER SIZE 

FASTENER TORQUE 

lb-ft 

(N.m) 

lb-ft 

(N.m) 

1/4" 

8

(11)

M4

(2)

3

5/16" 

17

(23)

M5

(4.5)

6

3/8" 

30

(40)

M6

(7.5)

10

7/16”

48

(66)

M8

(18)

25

1/2" 

74

(100)

M10

(37)

50

9/16”

106

(144)

5/8" 

148

(200)

3/4”

269

(364)

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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