download
INSTALLATION 1. Remove the screws from the rear corners of the bumper, two in each side. Figure 2 Figure 2 Bumper mounting screws, left side 2. Remove the eight screws along the bottom of the bumper. Figure 3 Figure 3 Lower bumper mounting screws Remove 2 screws in rear of bumper Remove 8 screws in bottom of bumper (4 per side) WARN INDUSTRIES PAGE 4 73465 A0 3. Lift the hood and remove the two screws from the top of the grille. Retain the hardware for use later. Figure 4 Figure 4 Grille fasteners 4. Remove the two plastic fasteners from the top of the grille. Retain the hardware for use later. Carefully pry the center pins up before removing the fasteners. Figure 5 Figure 5 Left grille fastener removal 5. Pull the grille free of the retaining clips with a “sharp” pull. Remove 2 screws Remove 2 plastic fasteners (1each side) Lift center pin then pry fastener out WARN INDUSTRIES PAGE 5 73465 A0 6. Remove five plastic fasteners from the top of the bumper. Two are behind the upper bumper support. Figure 6 Figure 6 Bumper fasteners 7. Pull the bumper corners free by pulling the ends rearward and out. The top of the bumper is snapped into plastic clips just below the fender corners, in front of the flares. Pull the bumper free. Figure 7 Figure 7 Left bumper end removal Remove 5 plastic fasteners (2 behind bumper not shown) WARN INDUSTRIES PAGE 6 73465 A0 8. Remove the two screws that hold each plastic mounting block in place and remove the blocks. Figure 8 Figure 8 LH bumper mounting block 9. Remove the three screws and remove the upper bumper support. Figure 9 Figure 9 Upper bumper support Remove 2 screws and remove plastic block Remove 3 screws Do not remove the nuts on top Bumper mounting block Upper bumper support WARN INDUSTRIES PAGE 7 73465 A0 10. Remove the 8 hex flange nuts and remove the bumper beam. Retain the hardware for bumper installation. Figure 10 Figure 10 Bumper beam, left side shown 11. Remove the four screws and remove the skid pan. Retain the hardware for reinstallation of the skid pan. Figure 11 Figure 11 Skid pan 12. Remove the molded plastic inner fender extensions by clipping or drilling out the rivets holding them to the bottom of the inner fenders. Figure 12 Remove 4 fasteners to remove skid pan Remove 4 flange nuts per side Bumper beam WARN INDUSTRIES PAGE 8 73465 A0 Figure 12 Left side fender extension 12. Locate the 1″ hole in the side of the frame behind the body mount. Drill a 1/2″ hole through the center into the inner wall. The Spacer Tube may be used as a centering tool. Repeat for opposite side. Figure 13 Figure 13 Outside left frame rail 13. Hold the Lower Frame Bracket in position and insert a 12mm bolt with 1/2″ lock washer and flat washer through the bottom hole in the Bracket and into the threaded hole in the frame. Do not tighten yet. Figure 14 Drill ½” hole through center of existing hole into inner frame wall Clip or drill rivets to remove fender extension Fender extension WARN INDUSTRIES PAGE 9 73465 A0 14. Slide a 1/2″ flat washer and Spacer Tube over a 1/2 x 4″ bolt and insert through the Lower Frame Bracket and Frame. Install 1/2″ lock washer and hex nut. Do not tighten yet. Figure 14 15. Slide an Upper Frame Bracket above the frame rail along the inside of the Lower Frame Bracket. Align the holes and insert two 7/16 x 1 1/2″ bolts through the holes and install a lock washer and hex nut on each. Do not tighten yet.
