SPECIAL INSTALLATION INSTRUCTIONS
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1 SPECIAL INSTALLATION INSTRUCTIONS WARN 4X FLARES FRONT AND REAR '98 TOYOTA HILUX DUAL-CAB As you read these instructions, you will 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! READ THIS BEFORE INSTALLATION: The installation of Warn Rear 4X Flares for the Hilux Dual-Cab requires the installer to drill two 3mm(1/8 inch) holes into the rear of the cab on each side. The holes are required for screw insertion for the attachment of the cab flare sections. Warn has determined that screws offer the most secure and reliable method of attachment. These instructions provide specific information for flare installation on the Toyota Hilux Dual-Cab. Use these instructions as a supplement to the General Instructions. NOTE: Surface preparation, tape application and basic fitting techniques can be found in the General Instructions. TOOLS REQUIRED Safety Glasses Drill Motor 3mm(.125 ) Drill Bit 5mm(.188 ) Drill Bit 6mm(.250") Drill Bit 10mm End Wrench or Socket #2 Phillips Screwdriver Hacksaw or Hand Shears Silicone Sealant Spring Clamps (optional) CAUTION: To avoid eye injury always wear safety glasses when operating power tools. Front Flare Installation 1. Remove any fender molding, and trim or remove any body side molding that will interfere with the front flare fit. (Figure 1) 2. Remove the mud flap (3 screws). It can be reinstalled after the flare is in place. Figure 1 Front Flare Location The bumper section may not fit some models. The bumper section should not be installed in this case. WARN Rev B0
2 3. Apply 2-sided tape to the front flare and bumper section per the General Instructions. Use a long section of tape for the front flare and a short section of tape for the bumper section*. Allow the tape to run at least 25mm long on each end of the part. * The bumper section may not fit some models. Do not install the bumper section in this case. Proceed with the flare installation and disregard references to the bumper section. NOTE: Do not remove the red tape liner at this time. Figure 2 Drill Holes in Flare And Apply Tape 4. Drill a 5mm hole through each of the three(3) dimples in the under side of the front flare and through each of the three(3) dimples in the bumper section. Also drill a 6mm hole through the bottom dimple in the rear of the flare for the mud flap fastener. (Figure 2) 5. Fit the flare in place on the vehicle. NOTE: Take special care to align the details of the flare with the corresponding body details. NOTE: The taped areas of the flare should fit tight against the fender. The tape will not stick the flare to the body if there are gaps. 6. Hold or clamp the flare in place. 7. Install the factory mud flap with the original fasteners. The flare should be positioned between the mud flap and the fender. Check the flare/fender alignment again. Slot the hole in the flare if any adjustment is needed. 8. Drill through each of the 5mm holes in the flare into the fender lip with a 3mm drill bit. (Figure 3) Figure 3 Transfer Holes into Fender NOTE: The three 3mm holes should not align with any existing holes in the fender. The existing holes may be too large for the flare WARN Rev B0
3 9. Attach the flare to the fender with three(3) (Figure 4) NOTE: Make sure the flare fits without gaps. NOTE: Slot the flare holes and push the flare tighter against the fender if necessary. 10. When the flare fits properly, tighten the 11. Drill through each of the 5mm holes in the bumper section into the bumper lip (2 holes) and air dam lip (1 hole) with a 3mm drill bit. (Figure 3) Figure 4 Install Screws in Front Flare 12. Attach the bumper section to the bumper and air dam with three(3) (Figure 5) NOTE: Make sure the bumper section fits without gaps and is aligned with the front flare. NOTE: Slot the bumper section holes and push the part tighter against the bumper if necessary. 13. When the part fits properly, tighten the Figure 5 Install Screws in Bumper Section* * The Bumper Section may not fit some models. The bumper section should not be installed in this case. WARN Rev B0
4 14. Remove the red tape liner. (Figure 6) NOTE: Start at one end and pull the tape liner in the direction of the flare. NOTE: To reduce the possibility of breaking the tape liner during removal, pull the flare edge away from the body slightly to relieve the pressure on the tape while pulling the liner past any pinch points. NOTE: If the tape liner breaks start again from the opposite end of the flare. 15. Trim the tape ends. 16. Remove the tape liner and trim the tape ends from the bumper section. Figure 6 Remove Red Tape Liner and Trim Tape Ends 17. Repeat steps 1-16 for the opposite side of the vehicle. Rear Flare Installation 18. Remove any fender molding, and trim or remove any body side molding that will interfere with the flare fit. (Figure 7) 19. Remove the rear mud flap (3 screws). It can be reinstalled after the flare is in place. Figure 7 Rear Flare Location WARN Rev B0
5 20. Apply 2-sided tape to the rear flare and cab section per the General Instructions. Use a long section of tape for the rear flare and a short section of tape for the cab section. Allow the tape to run at least 25mm long on each end of the flare and cab section. NOTE: Do not remove the red tape liner at this time. Figure 8 Drill Holes in Flare and Cab Section and Apply Tape 21. Drill a 5mm hole through each of the three(3) dimples in the under side of the rear flare and through each of the two(2) dimples in the bumper section. Also drill two(2) 6mm holes through the bottom dimples in the rear of the flare for the mud flap fasteners. (Figure 8) NOTE: The cab section should be installed on the vehicle first. The rear flare can then be installed and adjusted to match the cab section. 22. Fit the cab section in place on the vehicle. NOTE: Take special care to align the details of the flare with the corresponding body details. NOTE: The taped areas of the cab section should fit tight against the cab. The tape will not stick the flare to the body if there are gaps. 23. Hold the cab section in place and drill through each of the 5mm holes in the cab section into the vehicle cab with a 3mm drill bit. (Figure 9) Figure 9 Transfer Holes into Fender and Cab 24 Apply silicone sealant around each of the 3mm holes in the cab to seal out water. WARN Rev B0
6 25. Attach the cab section to the cab with two(2) (Figure 10) NOTE: Make sure the cab section fits without gaps. NOTE: Slot the cab section holes and push the part tighter against the bumper if necessary. 26. When the cab section fits properly, tighten the Figure 10 Install Screws in Cab Section 27. Fit the rear flare in place on the vehicle. (See Figure 11 for splash guard trim) Figure 11 Trim Splash Guard for Flare Clearance NOTE: Take special care to align the details of the flare with the corresponding body details. NOTE: The taped areas of the flare should fit tight against the fender. The tape will not stick the flare to the body if there are gaps. 28. Hold or clamp the flare in place. 29. Install the factory mud flap through the upper hole with the original screw. The flare should be positioned between the mud flap and the fender. Check the flare/fender alignment again. Slot the hole in the flare if any adjustment is needed. WARN Rev B0
7 30. Drill through each of the 5mm holes in the flare into the fender lip with a 3mm drill bit. (Figure 9) NOTE: The 3mm holes should not align with any existing holes in the fender. The existing holes may be too large for the flare 31. Attach the flare to the fender with three(3) (Figure 12) NOTE: Make sure the flare fits without gaps. NOTE: Slot the flare holes and push the flare tighter against the fender if necessary. 32. When the flare fits properly, tighten the 33. Install the remainder of the mud flap Figure 12 Install Screws in Rear Flare 34. Remove the red tape liner. (Figure 13) NOTE: Start at one end and pull the tape liner in the direction of the flare. NOTE: To reduce the possibility of breaking the tape liner during removal, pull the flare edge away from the body slightly to relieve the pressure on the tape while pulling the liner past any pinch points. NOTE: If the tape liner breaks start again from the opposite end of the flare. 35. Trim the tape ends. 36. Remove the tape liner and trim the tape ends from the cab section. Figure 13 Remove Red Tape Liner and Trim Tape Ends 37. Repeat steps for the opposite side of the vehicle. WARN Rev B0
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