INSTALLATION INSTRUCTIONS Part Number 69110 Hidden Winch Kit with special XD 9000 Short Drum Winch For Ford F-150 Truck 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! CAUTION DRILLING OPERATIONS CAN CAUSE FLYING METAL CHIPS. WEAR SAFETY GOGGLES. FLYING METAL CHIPS CAN CAUSE EYE INJURY. TOOLS REQUIRED 8 mm socket 7/16 socket and end wrench 10 mm socket 9/16 socket and end wrench 15 mm socket 5/8 end wrench 21 mm socket 3/4 socket or end wrench Saw or razor knife 15/16 socket and end wrench 1/4 drill bit and drill motor 3/8 hex socket (Allen) wrench Safety glasses Floor jack (optional) PARTS LIST PART NO. QUANTITY DESCRIPTION 69111 1 Winch Mount 69360 1 License Plate Bracket 68897 1 Fairlead Bracket 69358 1 Control Pack Bracket 68896 2 5/8-11 x 6 Bolt 68693 2 Spacer Tube 67845 2 Nut Plate 36299 1 Fairlead WARN 1 69367 Rev A0
Winch Mount Fairlead Bracket mounting holes Control Pack Bracket mounting holes Clutch lever access Frame mounting holes Lower winch mounting holes Also, lower fairlead bracket mounting holes Ground terminal access Bumper fastener access Figure 1 Winch Mount features (shown without winch) TORQUE SPECIFICATIONS BOLT SIZE TORQUE 1/4 8 ft. lbs. 3/8 30 ft. lbs. 7/16 50 ft. lbs. 1/2 75 ft. lbs 5/8 150 ft. lbs. NOTE: Follow the step-by-step sequence for fastest installation. Do not securely tighten bolts until directed. The hardware kits are designed for multiple applications. There may be fasteners that are not used in this application. 1. Install the Fairlead onto the Fairlead Bracket. The warning label should be on top. Use the 7/16 x 1 hex socket head bolts with lock washers and nuts. Tight the hardware. Figure 2 2. Feed the wire rope through the Winch Mount, and Fairlead and install the hook per Warn Operator s Manual. WARN 2 69367 Rev A0
3/8 x 1-1/2 bolts flat washers lock washers nuts Control Pack Bracket 1/4 x 1 bolts flat washers lock washers nuts 1/2 Nut plates (use with 1/2 hardware if factory tow loop hardware is not available) Fairlead Fairlead Bracket 7/16 x 1 socket head bolts lock washers nuts 3/8 x 1-1/2 bolts, lockwashers 1/2 x 2 bolts lock washers flat washers (Use if factory tow loop hardware is not available) 5/8 x 6 bolts flat washers spacer tubes shims (use washers as required) lock nuts Figure 2 Winch Mount and hardware exploded view (shown without winch) Cable release screw Bumper cap screw Grille stop screw Figure 3 Bumper cap hardware to be removed (quantity and position may vary) WARN 3 69367 Rev A0
3. Remove the screws along the top of the bumper (behind the grille) that secure the bumper cap, the cable release for the hood and the grille stops. Figure 3 Air deflector flap fasteners Figure 4 Air deflector flap fasteners 4. Remove the three (3) plastic fasteners that secure the rubber air deflector flap to the bottom of the bumper. The fasteners will be re-used. Figure 4 Remove these two nuts on each side to remove bumper 5. Disconnect fog lamp wires if so equipped. Figure 5 Bumper hardware to be removed 6. Use a 21mm socket to remove the four (4) nuts (2 per side) that hold the bumper to the frame. Figure 5 Remove the bumper by rotating the bottom forward and sliding it out from underneath the bumper cap. WARN 4 69367 Rev A0
1 3/4 1 15 3/8 4 5/8 Figure 6 Bumper grille trim dimensions 7. Trim the bumper grille as shown in Figure 6. It should be trimmed to the back edge of the bumper or 1-3/4. The grille can be left in place or removed for trimming depending on the tools used. A knife, saw or hand shears may be used. 8. Remove the tow loops if so equipped. 9. Lift the Winch Mount into position against the bottom of the frame. A couple of assistants or a floor jack are helpful. Loosely attach the Winch Mount to the bottom of the frame with the original tow loop hardware including the original nut plates inside the frame (or the 1/2 x 2 bolts, lock washers, flat washers and nut plates provided). If factory tow loops are being reinstalled, sandwich the Winch Mount between them and the frame as in Figure 7. Do not tighten. Factory tow loop hardware Figure 7 Winch Mount installed with tow loops WARN 5 69367 Rev A0
5/8 x 6 bolts with spacer tube through frame 1/2 hardware Nut plate inside frame Figure 8 Winch Mount installed without tow loops 10. Insert a 5/8 x 6 bolt with flat washer and Spacer Tube through the hole in the frame shown in Figure 8. Repeat for the opposite side of the vehicle. 11. Center the Winch Mount between the frame rails and insert as many washers as necessary to shim between the frame and Winch Mount. Figure 9 Use washers to shim as required for centering Figure 9 Insert shims between winch mount and frame 12. Push the 5/8 bolt through the Winch Mount and install a 5/8 lock nut. 13. Tighten the tow loop bolts. 14. Tighten the 5/8 bolts while insuring the Spacer Tubes are centered in the frame holes. 15. Attach the Control Pack Bracket to the top of the Winch Mount with 1/4 x 1 bolts, flat washers, lock washers and nuts. The bolts can be install pointing up. Do not tighten yet. WARN 6 69367 Rev A0
16. Install the Control Pack on top of the Bracket. Do not tighten yet. F1 A F2 Figure 10 Motor terminals NOTE: The Control Pack Cables and the terminals on the winch motor are identified with an A, F1 or F2. Be sure the Cables are connected to the correct terminals. See Figure 10. The light gage wire is a ground and should be connected to the terminal in the front of the motor along with the long black 2ga battery ground cable. Figure 11 See the Winch Instructions for additional wiring information. Upper Fairlead Bracket bolts License Plate Bracket Route black 2ga cable from battery and small ground wire from Control Pack, behind motor to Motor ground terminal Figure 11 Motor ground terminal WARN 7 69367 Rev A0
17. Attach the cables from the Control Pack to the winch. Route them so they can t be cut, melted or worn through. Install the ground wire from the Control Pack and the long ground cable from the battery to the front of the winch motor. The ground wire and cable can be routed behind and under the motor. Access to the ground terminal bolt is through the hole in the front of the Winch Mount. Figure 11 18. Reinstall the bumper by tilting the top and sliding the bumper under the bumper cap then rotating and lifting it into place. The bumper bolts may have slipped in the slots and will need to be re-aligned before the bumper will fully slip into place. Reinstall the nuts. Access to the inboard nuts is through large holes in the winch mount. Figure 12 Figure 12 Tilt bumper to install 19. Align the bumper side-to-side and vertically then tighten the hardware. 20. Adjust the Control Pack and Bracket to clear the bumper and cooler then tighten the hardware. 21. Reinstall the grille stops, cable release and remaining screws across the top of the bumper. CAUTION DRILLING OPERATIONS CAN CAUSE FLYING METAL CHIPS. WEAR SAFETY GOGGLES. FLYING METAL CHIPS CAN CAUSE EYE INJURY. 22. Hold the rubber air deflector flap against the lower rear lip of the Winch Mount. Transfer the three (3) 1/4 holes in the lip into the rubber flap with a drill motor and 1/4 bit or other suitable tool. Use the original press-in fasteners to attach the rubber flap to the winch mount. Trim the rubber flap along the bottom edge of the lip. 23. Loosen the upper Fairlead Bracket bolts and slide the License Plate Bracket under the flat washers. Align the License Plate Bracket and tighten the bolts. Install the license plate. Figure 11 WARN 8 69367 Rev A0