INSTALLATION INSTRUCTIONS Ascent-HD Front Bumper Part Number: 10691X Application: 2017-20 Ford SD F250/F350
G E N E R A L S A F E T Y P R E C A U T I O N S Your safety, and the safety of others, is very important. To help you make informed decisions about safety, we have provided installation and operating instructions and other information on labels and in this guide. This information alerts you to potential hazards that could hurt you or others. It is not possible to warn you about all potential hazards associated with this product, you must use your own good judgment. CARELESSINSTALLATION AND OPERATIONCANRESULTINSERIOUSINJURY OR EQUIPMENTDAMAGE. READ AND UNDERSTANDALLSAFETYPRECAUTIONSANDOPERATINGINSTRUCTIONSBEFOREINSTALLINGANDOPERATING THIS PRODUCT. This guide identifies potential hazards and has important safety messages that help you and others avoid personal injury or death. WARNING and CAUTION are signal words that identify the level of hazard. These signal words mean: WARNING signals a hazard that could cause serious injury or death, if you do not follow recommendations. CAUTION signals a hazard that may cause minor to moderate injury, if you do not follow recommendations. This guide uses NOTICE to call attention to important mechanical information, and Note: to emphasize general information worthy of specialattention.
W A R N I N G IMPACT AND MOVING PARTS ENTANGLEMENT HAZARD Failure to observe these instructions could lead to severe injury or death
• Always KnowYourWinch.TaketimetofullyreadtheInstructionsand/orOperationsGuide,and/orBasicGuidetoWinchingTechniques,inordertounderstandyourwinchanditsoperations. • Never work under vehicle before properly securing vehicle. • Always use appropriateand adequate care in lifting components into place. • Never work under vehicle before properly securing vehicle. • Always use appropriateand adequate care in lifting components into place. • Never use a jack to support the vehicle. • Always use jack stands in pairs to support the vehicle. • Always use jacks or jackstandsonly on a hard, stable, and level surface. • Never exceedthe ratedcapacity of a jack or jack stands. • Always verifythattheparkingbrakeisset,thetransmissionisinpark(automatic)orreverse(manual)andtherearwheelsareblockedbeforeworkingonvehicle. • Never work under vehicle before properly securing vehicle. • Always use appropriateand adequate care in lifting components into place. • Always insurecomponents willremainsecureduring installationand operation. • Always tighten all nuts and bolts securely, per the installationand operation. • Always performregular inspections and maintenance on the winch, winch mount and relatedhardware. • Always replace all wornor damaged parts before operating. • Never operatethisWARNproductwith damagedor missingparts. • Always useextremecautionwhendrillingonanyvehicle.Makesurethatallfuellines,brakelines,electricalwires,andotherobjectsarenotpuncturedordamagedwhen/ ifdrillingonthevehicle.Thoroughlyinspectthe areato bedrilled(onbothsidesofmaterial)priorto drilling,andrelocateanyobjectsthatmaybe damaged.Failureto inspecttheareato bedrilledmayresultin vehicledamage,electricalshock,fireorpersonalinjury. • Always use extremecautionwhencuttingand trimmingduring fitting. • Always wearsafetyglasseswheninstalling thiskit. A drillingoperationwillcauseflyingmetalchips.Flyingchipscan causeeyeinjury. • Always removejewelry and wear eye protection. • Never lean over battery while making connections. • Never route electrical cablesacrossanysharp edge, through or near moving parts, near parts that becomehot. Read installation and operating instructions thoroughly.
WARN INDUSTRIES, INC. 12900 S.E. Capps Road, Clackamas, OR USA 97015-8903, 1-503-722-1200, FAX: 1-503-722-3000
Customer Service: 1-800-543-9276 Dealer Locator Service: 1-800-910-1122 International Fax: 1-503-722-3005
107225A0
©2019 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
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C A U T I O N MOVING PARTS ENTANGLEMENT HAZARD Failure to observe these instructions could lead to minor or moderate injury
•
Part edges may be sharp!
• Alwaysuse properposture/ liftingtechniqueor get liftingassistancewhilehandlingand installingproduct.
Read installation and operating instructions thoroughly.
N O T I C E EQUIPMENT DAMAGE
• Never towvehicleby attachingatowbar to the eyeletsonthe bumper. • Donotattachtowbarsdirectlytothebumper. Damagetobumpermayoccur.WARNbumpersarenotdesignedtobeusedforflattowing. Consultwiththemanufacturerofyourtowbarsystemforthepropervehicletow bar brackets.. Read installation and operating instructions thoroughly. B E F O R E Y O U B E G I N • BEFORE YOU BEGIN READ INSTALLATION INSTRUCTION THOROUGHLY. N O T I C E
This product may interfere with driver assist systems such as adaptive cruise control and parking assist systems that have sensors or cameras installed in the bumpers or front grill area. If your vehicle is equipped with any of these systems or features, consult your vehicle owner’s manual before installing this product. These systems may need to bedisabled as a result of installing this product.
T A B L E O F C O N T E N T S Tools Required ................................................................................................. page 2 Torque Specifications....................................................................................... page 2 Parts List .......................................................................................................... page 3 Installation....................................................................................................... page 4-8 Maintenance/Care .......................................................................................... page 9
T O O L S R E Q U I R E D
- Standard wrenches - Standard sockets - Metric socket set
- 3/8” Drive Ratchet - ½” Drive Ratchet - Metric wrench set
- Torque wrench
- Phillip head screwdriver - Allen head wrench
T O R Q U E S P E C I F I C A T I O N S Please use the recommended torque specifications when assembling this product unless otherwise specified in the instructions.
FASTENER SIZE
FASTENER TORQUE
FASTENER SIZE
FASTENER TORQUE
lb-ft
(N.m)
lb-ft
(N.m)
1/4"
8
(11) (23) (40) (66)
M4 M5 M6 M8
(2)
3 6
5/16"
17 30 48 74
(4.5) (7.5) (18) (37)
3/8"
10 25 50
7/16”
1/2"
(100) (144) (200) (364)
M10
9/16”
106 148 269
5/8" 3/4”
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©2019 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
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P A R T S L I ST
ITEM PART NO. DESCRIPTION
QTY
ITEM
PART NO.
DESCRIPTION ½” Bolt strip
QTY
1
10691X 94888 94889 102483 101064 101065 101072 101067 101039 100975 100974 100511 100601 100604 100606
WARN Ascent HD 2017+ Ford SD Bumper
1 1 1 1 1
51 6.1 6.2
20296
4 1 1
2.1 2.2
Light Insert RH Light Insert LH
21279-W 21280-W
10691X DS mounting bracket 10691X PS mounting bracket
3 4
WARN Ascent DS Label
50246-HW WARN Super Duty HW Kit
4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9
10-24X3/4 Button head bolt (notallshown)
20 20 20 20
10-24 Machine screw nut #10 Split lock washer
#10 Flat washer
M14-2X50mm Hex head cap screw
4 4 4 8 8 8 8
M14-2 Hex head nut M14 Lock washer M14 Flat washer ½-13 Hex head nut ½” Lock washer ½” Flat washer
4.10 4.11
107225A0
©2019 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
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I N S T A L L A T I O N I N S T R U C T I O N S
1. Start by removing four bolts around tow hook on each side of vehicle. This will require an 18mm socket. (Fig. 1)
Figure 1
2. Next, with the help of someone holding the bumper in place, remove the four 15mm bolts from the bumper supports on both sides of vehicle. (Fig. 2)
Figure 2 3. The bumper can now be removed. (Be careful when removing bumper if vehicle has a block heater, as this will have to be unplugged during this step.)
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I N S T A L L A T I O N I N S T R U C T I O N S
4. With the bumper off the vehicle, you can now remove the tow hooks by removing the four 18mm bolts located under the top of frame rail. (Fig. 3)
Remove with 18mm socket
Figure 3
5. Next, using 18mm socket remove the two nuts on either side of the frame attaching frame horns to frame. Set bolt strips and nuts aside as they will be used in the installation of WARN bumper. (Fig. 4)
Figure 4
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I N S T A L L A T I O N I N S T R U C T I O N S
6. Optional: If you are installing a winch with this bumper installation, do so now. Use the bracket or clamps supplied with the winch to mount the control pack; be sure to install the winch ground strap before installing the winch in the bumper. Once the control pack is installed on the winch, insert the winch into the bumper. The control pack should be facing up with the four front mounting holes facing forward. Insert the winch by first tipping the end with the clutch lever up and inserting the control pack end in the bumper first. Then insert the clutch lever end in the bumper. Use the hardware supplied with the winch to properly mount the winch to the bumper. Follow the instructions supplied with the winch for the proper bolt location. The winch comes with two different length 7/16” bolts, so read the instructions with the winch to ensure the proper locations.
If not installing a winch, a license plate may be installed onto the front face of the bumper. (Hardware not included.)
7. Start by installing mounting bracket as shown below. Do not fully tighten the hardware. (Fig. 5)
Figure 5
8. Install the two light boxes (94888 and 94889) into the bumper on the RH and LH side respectively. Use the provided #10-24 Bolts, flat and lock with nuts to attach them to the bumper and tighten them with 10mm socket wrench and 3mm allen wrench (50246-HW). (Fig 6-7)
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I N S T A L L A T I O N I N S T R U C T I O N S
Figure 6
Figure 7 9. Once the brackets are loosely installed, with the help of two other people, lift the bumper into place.
10. With the bumper in place loosely install using the bolt strips and 1/2" flat and lock washers with nuts (50246-HW). (Fig.8)
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I N S T A L L A T I O N I N S T R U C T I O N S
Figure 8 11. Next hold the bumper into desired position on the truck. NOTE: WARN recommends a MINIMUM gap of 3/8” at the outer fenders and headlights to prevent paint damage in normal operation. 12. With bumper in position you can begin tightening all hardware. Tighten all fasteners fully, beginning with frame mounts. Then tighten all mount-to-bumper fasteners.
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I N S T A L L A T I O N I N S T R U C T I O N S
M A I N T E N A N C E / C A R E 1. Inspect all parts on the winch, winch mount, and related hardware prior to each use. Replace all hardware that appears rusted or deformed. 2. Inspect all nuts and bolts on the winch, winch mount,, and related hardware prior to each use. Tighten all nuts that appear to be loose. Stripped, fractured, or bent bolts or nuts need to be replaced.
3. Check all cables prior to use. Replace cables that look worn or frayed.
4. Check all moving or rotating parts. Remove debris that may inhibit the part from moving freely.
CARELESS INSTALLATION ANDOPERATION CAN RESULT IN SERIOUS INJURY OR EQUIPMENT DAMAGE. READ AND UNDERSTANDALLSAFETY PRECAUTIONS AND OPERATING INSTRUCTIONS BEFORE INSTALLING AND OPERATING THIS PRODUCT.
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