INSTALLATION INSTRUCTIONS

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1 INSTALLATION INSTRUCTIONS For and Front Bumper and Winch Mount For Ford Super Duty Trucks As you read these instructions, you may see NOTES, CAUTIONS and WARNINGS. Each message has a specific purpose. NOTES are additional information to help you complete a procedure. CAUTIONS are safety messages that indicate a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. A CAUTION may also be used to alert against unsafe practice. WARNINGS are safety messages that indicate a potentially hazardous situation, which, if not avoided could result in serious injury. CAUTIONS and WARNINGS identify the hazard, indicate how to avoid the hazard, and advise of the probable consequence of not avoiding the hazard. PLEASE WORK SAFELY! NOTE: Factory driving/fog lights cannot be used with this kit. Also, this installation requires some drilling. Holes will need to be drilled for 1/4 and 7/16 fasteners. The holes for the 7/16 fasteners will be drilled through 1/4 steel. PARTS LIST PART NO. QUANTITY DESCRIPTION Bumper Mounting Bracket, Front, Left Mounting Bracket, Front, Right Mounting Bracket, Bottom Fairlead Opening Filler Parts Pack, Bumper Light Kit Parts Pack, Winch Mount Frame Extension, LH Frame Extension, RH Winch Mounting Bracket Intermediate Brace, LH Intermediate Brace, RH License Plate Bracket Extender Plate Fairlead Mounting Plate Shim Plate Solenoid Mounting Bracket Light Backing Plate WARN Rev C0

2 TORQUE SPECIFICATIONS BOLT SIZE TORQUE 7/16 inch 45 lb. ft. (40.7 N-m) 1/2 inch 60 lb. ft. (67.8 N-m) 5/8 inch 90 lb. ft. (101.7 N-m) 1. Take note of the gap between the top of the bumper and the bottom of the grille and light area. Compare the driver side to the passenger side. The new bumper mounting brackets and winch mounting framework of your kit are provided with slotted holes to allow you to fine tune bumper alignment. 2. Remove the bumper and discard. First detach the rubber air baffle from the back of the bumper by prying out the three plastic fasteners. NOTE: Try not to damage these. You will use these later to reattach the air baffle. Disconnect the block heater plug and wiring (if you have one). Remove the two bolts per side, which are located just outboard of the tow loops. Go back and forth between each bolt, loosening a little bit more each time. If initially, one bolt is completely backed out, the nut plate on the backside of the bumper will spin when you try to back out the other bolt. 3. Remove the license plate. 4. Remove the tow loops (retain the fasteners) 5. Secure the cosmetic plates on the ends of the truck s frame rails by bending the bottom tabs up. You can remove these if you like, but if you do, frame coating material may come off with them. 6. Install the frame extensions as shown. See Figure 1. Leave the fasteners hand tight. NOTE: Due to vehicle variation, you may have to open up a hole in the frame rail to get all three bolts installed. Use the supplied ½ x 2 bolts, lock washers and nuts. Figure 1 WARN Rev C0

3 7. Assemble the winch to the winch-mounting bracket as shown. See Figures 2a, 2b, and 2c. Securely tighten the fasteners. Figure 2a Figure 2b WARN Rev C0

4 Note: If you are installing a 16.5ti winch, you must install the special solenoid pack bracket supplied in this kit. Figure 2c, follow the instructions supplied with the winch for correct installation. Tighten control pack. 8. Attach the winch-mounting bracket to the frame extensions as shown. See figure 3. Leave the nuts on the carriage bolts somewhat loose. Measure from a fixed point on one side of the grill to a point on the winch mount on the opposite side of the vehicle. Measure from the other side of the grill to the winch mount on the opposite side of the vehicle. Before tightening the fasteners that attach the frame extensions to the frame, center the winch mount as much as possible to the grill. Use a pry bar to force the winch mount either way. Insert the pry bar between the frame bracket and the inside wall of the frame rail and force the winch mount either way while tightening. This will help in aligning the bumper to the front of the vehicle. Torque the fasteners that attach the frame extensions to the frame to 60 ft/lb. Once the frame brackets are tightened, raise the winch mount up half of the slots and tighten to ft-lbs. This will be the starting position of the bumper alignment. (If the winch interferes with the power steering cooler, see p.9) WARN Rev C0

5 Figure 3 9. If you are using a Warn lb winch, remove the bracket that attaches the solenoid box to the winch. Notice the position of bracket while removing. Re-attach the solenoid box using the bracket supplied with the winch mount. Torque the two nuts that attach the solenoid box to the bracket to 8 ft/lb. Leave the bolt that attaches the bracket to the winch finger tight. 10.Install the front bumper mounting brackets to the new front bumper. See Figure 4a and 4b. There is a left and right hand bracket. Place the appropriate bracket on the inside of the bumper flange and insert a ½ x 1-1/2 bolt with flat washer through the bumper and then the bracket. Install a flat washer, lock washer, and nut onto the bolt. Repeat this for all three bolthole locations on each side of the bumper. Leave finger tight. Once the left and right brackets are installed, use an angle meter or level to verify that the brackets are parallel to the front face of the bumper. There is sufficient slop in the bolt-holes to align the brackets. Once the brackets are parallel and aligned to the bumper, torque the ½ bolts to the 60 ft/lb. WARN Rev C0

6 Figure 4a. Front bumper mounting bracket, Left side shown. WARN Rev C0

7 Figure 4b. Front bumper mounting bracket, Right side shown. 10. Using a floor jack and jack stands, or a couple of buddies, install the new bumper to the winch mounting plate. Use the supplied ½ x 1-1/2 bolts, washers, lock washers, and nuts. Seven of the eight bumper mounting bolts should be installed from the front and the driver s side inner top bolt needs to be installed from the back. Align the bumper from side to side by having an even gap between the side tubes and the body. Slightly tighten the 8 bolts. Measure the distance from the top of the bumper to the lights. There should be approximately ½ to 1 gap. Determine if the bumper needs to move, if so record the measurement. Remove the bumper. Adjust the winch-mounting bracket vertically to desired position. See Figure 5a AND 5b. Securely tighten the fasteners that attach the frame extensions to the winch-mounting bracket once the vertical position is set. WARN Rev C0

8 Figure 5a. Approximately 1 gap between top of bumper and amber light. WARN Rev C0

9 Figure 5b. 11. Once the vertical bumper position is found and the bumper has been removed from the winch mount, adjust the winch mount to desired position and retorque the fasteners to ft-lbs. Install the intermediate braces so that the 5/8 bolts are all the way forward in the slotted frame holes. Leave the fasteners hand tight. NOTE: The nut on the rod is installed inside the frame rail. See Figure 6. Using the upper and lower guide holes, mark and drill with 7/16 bit, through the sides of the winch mount bracket (lower hole), and through the intermediate braces (remove braces to drill holes, then reinstall). 7/16 fasteners are used for the upper holes and 7/16 carriage bolts for the lower holes. See Figure 6. Attach the intermediate braces to the upper brackets and winch mount bracket. Securely tighten the lower 7/16 fasteners and the 5/8 intermediate brace fasteners. WARNING Drilling operations can cause flying metal chips. WEAR SAFETY GOGGLES. Flying metal chips can cause eye injury. WARN Rev C0

10 Figure Re-attach the bumper with mounting brackets to the winch mount. Leave the fasteners hand tight. Check the bumper for side-to-side alignment with the truck and then tighten the ½ fasteners. NOTE: Route the winch s power leads to the battery now (See winch instructions). 13. Install the bottom bumper bracket to the bottom of the winch plate and the back edge of the bumper. Use the 7/16 x 1-1/2 bolts, washers, lock washer, and nuts. See Figure 7. Access holes in the bottom of the bumper are used for the bolts to the winch mount and use the tow hook holes for access to the bolts to the bumper. Torque the 7/16 fasteners to 50 ft/lb. WARN Rev C0

11 Figure 7. Bottom bumper bracket. 14.Attach the fairlead and front license plate mounting bracket (if your state requires a front plate). See Figure 8a. Insert the license plate mounting bracket between the fairlead and winch mount. Use the 7/16 fasteners supplied with the winch. WARN Rev C0

12 Figure 8a. Using a winch. If you are not using a winch, install the fairlead filler plate and bolt the license plate to that. The filler plate is supplied to cover up the large opening in the front of the bumper. It attaches to the winch mount in the same place as the fairlead. Use the supplied 7/16 fasteners to install. Access holes have been cut into the front of it for help in attaching. Figure 8b. Not using a winch. WARN Rev C0

13 20. Attach the rubber air baffle to the extender plate. 21. If you have a block heater plug, use the provided zip-ties to secure it behind the bumper. 22. Install the supplied Warn 5 Stainless Steel lights to the light ports in the bumper. Insert the light mounting bolt down through the light mount tab and then install the light backing plate under the light mounting tab and tighten the light to the tab. See Figure 9. Wire the Warn lights per the instructions supplied with the lights. Figure 9 WARN Rev C0

14 23. Install the factory tow hooks. If you are using the one piece cast style, install the tow hooks using the original hardware. Insert the tow hook through the opening of the front bumper. The tow hooks should be mounted to the underside of the frame extension. From the backside of the bumper, insert the three bolts through the top of the frame extension and then the tow hook. The tow hook must be installed on the bottom side of the frame extension. See Figure 10a. Once the tow hook is snug to the frame extension, position it from side to side to align with the bumper opening. Torque the bolts to original spec. Repeat this for the opposite side. Figure 10a WARN Rev C0

15 If you are using the welded tow hook, the three nuts that are fusion welded to the tow hook must be removed before installation. See figure 10b and 10c for nut removal. Place the tow hook in a vise as shown in Figure 10b. Using a hammer, hammer the tow hook downward, thus breaking the nut loose. Once the nut is loose, use a pry bar to pop the nut off of the tow hook. See Figure 10c. Repeat this for all three nuts and the other tow hook. Figure 10b WARN Rev C0

16 Figure 10c Once the nuts are removed from the tow hooks, install them to the frame extensions. Insert the tow hook through the opening of the front bumper. The tow hooks should be mounted to the underside of the frame extension and the tow hook should be pointing downward. From the backside of the bumper, insert the three M12 x 55mm bolts through the top of the frame extension and then the tow hook. The tow hook must be installed on the bottom side of the frame extension. See Figure 10a. Use the supplied M12 nuts, ½ lock washers to tighten the tow hooks. Once the tow hook is snug to the frame extension, position it from side to side to align with the bumper opening. Torque the bolts to original spec. Repeat this for the opposite side. WARN Rev C0

17 Relocation of Power Steering Cooler Some models of Ford Super Duty trucks have an extra large power steering cooler, which will interfere with the winch when the Warn Bumper/Semi-Hidden winch mount 63600/63398 is being installed. When this occurs, the cooler should be relocated up behind the grille as shown below. The following parts are required. They are available at any NAPA Auto Parts store as well as most other parts stores: 3/8 Transmission Oil Cooler Hose, NAPA #H1937, two 12 pieces 3/8 Hose Coupler Fitting, NAPA #90-552, two required Screw Type Hose Clamp, four required Tie Wraps, approx. 12, two required Remove the grille and the cooler from the vehicle. Lengthen the factory hoses using the coupler fitting, 12 hose sections and hose clamps. Install hoses onto cooler and use the tie wraps to loosely install the cooler as shown. Reinstall the grille and then tighten the tie wraps securely. WARN Rev C0

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