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©2016 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.

 1 

98178B0

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 Front Bumper

Part Number: 97684

Application:  

2016+ Toyota Tacoma

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.

Содержание 97684

Страница 1: ...delectricalterminals Alwaysinstallterminalbootsasdirectedininstallationinstructions Alwaysuseappropriateandadequatecareinliftingcomponentsintoplace Alwaysinsurecomponentswillremainsecureduringinstallationandoperation Alwaystightenallnutsandboltssecurely pertheinstallationinstructions Alwaysperformregularinspectionsandmaintenanceontheplowmechanism fasteners cableandrelatedhardware Alwaysreplaceallw...

Страница 2: ... 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 recommend...

Страница 3: ... 12 B5 2146 7 16 Lock Washer 4 B6 220026 7 16 Flat Washer 12 B7 2583 7 16 14 Hex Nut 4 B8 15834 7 16 14X1 3 4 Hex Capscrew 2 B9 3693 Flat Spacer 4 B10 91541 10 24X1 Stainless Screw 20 B11 100661 9 16 LOCKING PLUG 6 ID No Item No Description Qty A1 97751 Bumper 1 A2 97943 Frame Bracket LH 1 A3 97942 Frame Bracket RH 1 A4 95458 Light Bracket RH 1 A5 95438 Light Bracket LH 1 A6 97986 Support Bracket ...

Страница 4: ...remove the front facia plastic by first removing the screws and plastic push clips from the inner fender skirt That will allow you to reach between fender skirt and plastic facia to release clips 3 Unclip and remove the plastic cover plate attached to the aluminum cross bar 4 Remove the four fasteners from underneath the bumper Figure 1 Figure 2 Figure 3 Unclip Figure 4 Remove ...

Страница 5: ...nut from the ends of the brackets Retain as you will be reinstalling later 7 Remove the three nuts securing the aluminum frame extension Remove extension Retain the nuts as you will be reusing them Repeat for other side 8 Remove the grille insert a Unsnap the six clips to remove the light covers from grille b Reach through opening behind the grill to unsnap the 19 plastic clips and two wire retain...

Страница 6: ...used WARNING Alwaysuseextremecautionwhencuttingandtrimmingduring fitting Makesurethatallfuellines brakelines electricalwires andotherobjects arenotpuncturedordamagedwhencuttingonthevehicle Thoroughlyinspectthe areatobecut onbothsidesofmaterial priortocutting andrelocateanyobjects thatmaybedamaged Failuretoinspecttheareatobecutmayresultinvehicle damage electricalshock fireorpersonalinjury 12 After ...

Страница 7: ... to attach bumper supports Do not remove the tow hook bolts 16 Before installing frame bracket you will need to cut out a small notch in the plastic air shroud a Hold frame bracket in place and mark area on shroud to notch enough to clear the frame extension bracket Carefully cut notch and fit up bracket b Slide new frame bracket over the three bolts left where you removed the aluminum frame exten...

Страница 8: ...g each bracket with one 7 16 bolt B8 two spacers B9 one washer B6 lock washer B5 and nut B7 Refer to exploded view on page 3 19 Fasten the support bracket A6 using the hardware previously removed in step 13 Connect support bracket to the frame bracket using the 7 16 bolt B8 washers B6 lock washers B5 and nut B7 hardware found in your hardware kit Refer to exploded view on page 3 Thread the hardwar...

Страница 9: ...page 3 Do not tighten at this time Repeat for other side 23 Insert the last remaining 7 16 hardware just below the four bolts just installed 24 Make sure there is not too much space between the frame brackets and the bumper The bumper should be centered from side to side on front fenders 25 Tighten all frame bracket hardware Double check the frame brackets to vehicle 26 Check the height of the bum...

Страница 10: ... installing optional Ascent bar accessories plug unused holes with provided hole plugs B11 Refer to exploded view on page 3 32 Your installation is now complete 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 hardwa...

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