INSTALLATION INSTRUCTIONS Trans4mer Grille Guard 35095 (Black) & 35096 (Chrome) Dodge Dakota / Durango 4x4 Trucks Parts List: Part No. Quantity Description 62969 1 Frame Ext, R.H. 62968 1 Frame Ext, L.H. 62965 2 Brace 35163 2 Side Member, Black 35164 Side Member, Chrome 29366 1 Tube, 2-1/2, Black 29399 Tube, 2-1/2, Chrome 29365 1 Tube, 1-1/2, Black 29398 Tube, 1-1/2, Chrome 29146 2 Washer, Nylon, 1-1/2 29147 2 Washer, Nylon, 2-1/2 62959 2 Shim Plate Torque Spec 3/8 31 lb/ft(42 N-m) 7/16 50 lb/ft(68 N-m) 1/2 75 lb/ft(102 N-m) This WARN Trans4mer system can be customized to give your Dakota or Durango a wide variety of looks, front-end protection and winch mounting capability. The system starts with this strong two-tube Grille Guard that attaches to the truck's frame with brackets designed by Warn engineers to handle up to a 9000 lb Winch. It is durable and good looking, even as a stand alone Grill Guard, but can be easily upgraded with some great options! You can add a third large size tube (Light Bar) that adds even more protection and includes tabs for mounting auxiliary lights. The tubes can be mounted in a variety of positions to achieved the look and function that you desire. You can mount a Winch Carrier Bracket that provides a permanent mount for a Warn winch. You may also add a Receiver Bracket that will handle the Warn Multi-mount winch system, a draw bar or any other accessory that fits the standard 2 inch receiver tube. Finally, Brush Guards that protect the headlights and front corners of the truck can be easily added to any of the options above. WARN Page 1 62961 RevA0
1. Remove bumper. Opening vehicle hood will expose bumper bolts to be removed, (2 per side). (Figure 1). The (5) plastic push fasteners located under bumper must also be removed. Be sure to disconnect any wiring or other items that may interfere with bumper removal. Leave factory bumper brackets attached to frame (Figure 2). FIGURE 1 BUMPER BOLTS 2. Remove body mount bolt and rubber from inside the front end of each frame rail. Remove 2 or 3 bumper bracket nuts (depending on vehicle) from inside each frame rail, then install the Frame Extensions and Shim Plates, inside the frame rails onto the factory bolts. (Figure 2) Leave nuts slightly loose. Note: Shim Plates may be needed to obtain a 32 distances between the outside surfaces of the Frame Extensions. Shim Plates are to be placed between Frame Extension and inner wall of frame. Note: If your vehicle had only (2) factory nuts install the supplied 1/2 x 1-1/4 bolt, lockwasher and nut to rear hole of Frame Extension, as shown (Figure 2). Leave fasteners slightly loose. WARN Page 2 62961 RevA0
FIGURE 2 FACTORY BUMPER BRACKET L.H. FRAME EXTENSION 1/2 x 1-1/4 BOLT LOCK WASHER NUT FACTORY NUTS REMOVE BODY MOUNT RUBBER INSULATOR SHIM PLATE 3. Cut slots into plastic lower bumper as shown in Figure 3. Note: Use CUTOUT A if you are installing the Diagonal Braces, use CUTOUT B if you are not installing the Diagonal Braces. Note: Use either ILLUSTRATION (1 or2), which ever best resembles your vehicle. FIGURE 3 WARN Page 3 62961 RevA0
ILLUSTRATION 1 ILLUSTRATION 2 WARN Page 4 62961 RevA0
4. If a Winch Carrier or Receiver Bracket is being installed, the Diagonal Braces must also be installed at this time. Use the supplied 3/8 x 1-1/2 bolt and nylock nut. Tighten fasteners fairly tight, but still allowing Diagonal Braces to be adjusted, Figure 4. FIGURE 4 3/8 x 1-1/2 BOLT NYLOCK NUT FRAME EXTENSION DIAGONAL BRACE 5. Reinstall bumper with Frame Extensions and Diagonal Braces (if installed) protruding through plastic. Tighten bumper bolts securely, Figure 5. Reattach any fasteners or other items previous removed. FIGURE 5 WARN Page 5 62961 RevA0
6. Install Side Members onto outer surface of Frame Extensions as shown in Figure 6. Install Winch Carrier and Large Tube with Nylon Washers at top of Side Members also shown in Figure 6. NYLON WASHER LARGE TUBE SMALL TUBE FIGURE 6 SIDE MEMBER 3/8 x 1 BUTTON HEAD BOLT WINCH CARRIER 7/16 x 1-1/4 ROUND HEAD BOLT LOCKWASHER NUT 7. The forward ends of the Diagonal Braces attach to bottom of Winch Carrier at rear winch mounting holes. (Figures 8). FIGURE 8 3/8 x 1-1/2 BOLT LOCKWASHER WARN Page 6 62961 RevA0
8. If the Trans4mer is being installed only as a gille guard and a winch is not being mounted at this time, install the tubes in any desired position. If the Winch Carrier or Receiver Kit is being added, install a tube only in the top position and then refer to the specific instructions packaged with those items. Tighten the fasteners securely. 9. Install the winch as described in the Winch Installation Instructions, except use the 3/8 x 1-1/2 bolts thru the braces at the rear winch mounting holes. 10. Hold Side Members in alignment with bumper and tighten all fasteners. Reinstall body mount. 11. Install smaller tube above winch. WARN Page 7 62961 RevA0