Warn 96640 Installation Instructions Manual Download Page 7

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96616A1

Figure 10

Figure 11

Figure 12

11.  Remove the rest of the exterior components from stock 

bumper that will be used on new bumper.

 

You are now ready to install your new bumper.

 

NOTE:  On Hemi models, you can either 

remove the exhaust tips or just loosen the 

clamp and angle tips 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.  

NOTE:  

The brackets are marked left and right hand.

13.  With assistance:

 

a.  Slide bumper onto brackets.

 

b.  Install mounting hardware (loosely).  Refer to page 3.

 

c.  Center bumper. 

 d. 

 Tighten all hardware

.

NOTE:  Make sure to check for tailgate clearance height 

and adjust bumper up and down for the appropriate 

clearance.

  

 

C A U T I O N

•  Always

 use assistance when moving or lifting heavy parts.

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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