INSTALLATION INSTRUCTIONS WARN ASCENT HD Part Number: 110912-14-IM Application: 202 4 Chevrolet HD
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. CARELESS INSTALLATION AND OPERATION CAN RESULT IN SERIOUS INJURY OR EQUIPMENT DAMAGE. READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND OPERATING INSTRUCTIONS BEFORE INSTALLING AND OPERATING 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 appropriate and adequate care in lifting components into place. • Never work under vehicle before properly securing vehicle. • Always use appropriate and 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 jack stands only on a hard, stable, and level surface. • Never exceed the rated capacity of a jack or jack stands. • Always verify that the parking brake is set, the transmission is in park (automatic) or reverse (manual) and the rear wheels are blocked before working on vehicle. • Never work under vehicle before properly securing vehicle. • Always use appropriate and adequate care in lifting components into place. • Always insure components will remain secure during installation and operation. • Always tighten all nuts and bolts securely, per the installation and operation. • Always perform regular inspections and maintenance on the winch, winch mount and related hardware. • Always replace all worn or damaged parts before operating. • Never operate this WARN product with damaged or missing parts. • Always use extremecautionwhendrillingonanyvehicle.Makesurethatall fuellines,brakelines,electricalwires,andotherobjectsarenotpuncturedordamagedwhen/if drillingon thevehicle.Thoroughlyinspectthe area to be drilled (on both sides of material) prior to drilling, and relocate any objects that may be damaged. Failure to inspect the area to be drilled may result in vehicle damage, electrical shock, fire or personal injury. • Always use extreme caution when cutting and trimming during fitting. • Always wear safety glasses when installing this kit. A drilling operation will cause flying metal chips. Flying chips can cause eye injury. • Always remove jewelry and wear eye protection. • Never lean over battery while making connections. • Never route electrical cables across any sharp edge, through or near moving parts, near parts that become hot. 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
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©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!
• Always use proper posture / lifting technique or get lifting assistance while handling and installing product.
Read installation and operating instructions thoroughly.
N O T I C E EQUIPMENT DAMAGE
• Never tow vehicle by attaching a tow bar to the eyelets on the bumper. • Do not attach tow bars directly to the bumper. Damage to bumper may occur. WARN bumpers are not designed to be used for flat towing. Consult with the manufacturer of your tow bar system for the proper vehicle tow bar brackets.. Read installation and operating instructions thoroughly.
B E F O R E Y O U B E G I N
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 be disabled 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 4-10 Maintenance/Care ........................................................................................ page 10 T O O L S R E Q U I R E D
- Plyers - Body Pry Tool
- 7/16” Socket Wrench - 7/16” Open End Wrench - 9/16” Socket Wrench - ¾” Socket Wrench
- ¾” Open End Wrench - 18mm Open End Wrench - T10 Star Head Socket Wrench - Wire Cutters
- 7mm Socket Wrench - 10mm Socket Wrench - 15mm Socket Wrench - 18mm Socket 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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INCLUDED PARTS DESCRIPTION ASCENT BUMPER (23172)
HARDWARE KIT
PART NO. 50250-HW 50250-HW 50250-HW 50250-HW 50250-HW 50250-HW 50250-HW 50250-HW 50250-HW 50250-HW 50250-HW 50250-HW 50250-HW 50250-HW 50250-HW
QTY
QTY
DESCRIPTION 3/8"-16 X 1”, Yellow Zinc Hex Cap Bolt, Grade 8 3/8", Yellow Zinc Flat Washer, Grade 8 3/8", Yellow Zinc Lock Washer, Grade 8 1/4"-20 X 1”, Yellow Zinc Hex Cap Bolt, Grade 8 1/4"-20, Yellow Zinc Hex Nut, Grade 8 1/4", Yellow Zinc Flat Washer, Grade 8 1/4", Yellow Zinc Lock Washer, Grade 8 1/2", Yellow Zinc Lock Washer, Grade 8 1/2”, Yellow Zinc Flat Washer, Grade 8 ½”-13, Yellow Zinc Hex Nut, Grade 8 10-24 x 3/4” Button Head Cap Screw, Stainless Steel 10-24 Hex Nut, Stainless Steel #10 Split Lock Washer, Stainless Steel #10 Flat Flasher, Stainless Steel 1-1/4” Plastic Sensor Plug
ITEM
4 4 4 4 4 4 4 8 8 8
1 1 1 1 4 1 1
1 2 3 4 5
22226 22227 23151 20296 94888 94889
6 7
1
20 20 20 20 4
3
2
4
6
7
5
3
3
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©2019 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
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1. Use a T10 star head socket wrench to remove the two (2) bolts from both the passenger and driver side wheel wells. Figure 1.
2. Use a body pry tool to carefully remove the front of the fender flare away from the body. Use a 7mm socket wrench to remove the bolt on the valance. Figure 2.
3. With the 7mm bolt removed use a body pry tool to remove the valance from the truck. Figure 3.
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©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
4. Use a 10mm socket wrench to remove the two (2) bolts at the base of the grill. Figure 4.
5. Use a body pry tool to remove the nine (9) push pins holding the grill cover. Figure 5.
6. Use a T10 socket wrench to remove the two bolts holding the hood latch on. With the hood latch taken off you can remove the grill cover. Figure 6.
7. Use a 10mm socket wrench to remove the four (4) bolts on the top of the grill. Figure 7.
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©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
8. With the bolts removed, carefully take the grill off the truck. While taking off the grill, unplug the camera harness on the passenger side of the truck. Figure 8.
9. From under the truck: use a 15mm socket wrench to remove the two (2) back bolts on the bumper support bracket on both sides. Figure 9.
10. With the grill gone you can access the bumper mounting bolts on the top deck. Use a 15mm socket wrench to remove the two (2) bolts one of the top (Figure 9) and one on the bottom (Figure 10). The bumper can now be removed from the truck. Figure 10-11.
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©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
11. As you remove the bumper, unplug the sensor, heater plug, and lower louver harnesses located on the driver side of the truck. Figure 12.
12. If equipped, remove the factory tow hooks by using an 18mm socket wrench to unfasten the two (2) bolts in the frame. Figure 13.
13. Use a 15mm socket wrench to take four (4) bolts holding the mounting plates to the frame horns. Figure 14.
1 4 . If equipped, remove the engine heater plug located on the driver side of the truck bumper. Push the bumper in against the spring and turn counterclockwise, once unclipped pull out from the bumper. Figure 15.
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©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 5 . Carefully remove the four sensors and sensor housings from the bumper by spreading the housing clips out and pushing the sensor out simultaneously. Make sure to mark the position of each housing for installing into the bumper. Figure 16.
1 6 . Remove the sensor housings from the bumper by pressing the retainer clips in on the sides and pushing the housing out. Figure 17.
1 7 . Install the two mounting brackets (22225 and 22226) using a 15mm and 18mm socket wrench and the OEM tow hook bolts and bracket bolts removed during steps 12-13. Figure 19.
1 8 . Reverse the process in step 16 to install the heater plug into the driver side mounting bracket. Reconnect the heater plug wiring harness before mounting the bumper. Figure 20.
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©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
19. Using the provided four (4) bolt stacks of 3/8”-16 yellow zinc hex bolt, flat washers, lock washer, and hex nut, loosely install the backer strip (22251) to both brackets (22226 & 22227). Center the backer strip with the grill and fully tighten with a 9/16” socket wrench. (50250-HW) Figure 21.
20 . Using the provided epoxy, secure all four (4) OEM sensor housings in their appropriate sensor cutout in the bumper (110912-4). Figure 22.
21 . After the epoxy has cured, fully seat all four (4) sensors into the sensor housings being mindful not to distort the rubber sensor isolator that sits around the sensor tip. Be sure both sides of the sensor housing are fully clipped on the sensor. 22. Route and zip tie the factory wiring harness to the bumper (110912-4) with the main factory connector being on the passenger wing.
23 . Install the light housings (94888-94889) into the bumper using the #10 stainless steel bolts, flat/lock washers and nuts (50250-HW). Figure 23.
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©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
24. With assistance, lift the bumper up to the brackets (22226 & 22227) and secure it loosely using the provided four (4) bolt strips (20296) and eight (8) 1/2”-13, yellow zinc hex nut, flat washers, lock washer. Figure 24-25. (50250-HW)
2 5 . With assistance of two, lift and center the bumper to the vehicle and using an ¾” open end wrench, fully tighten down the eight (8) ½”-13 nuts securing the bumper (23172) to the brackets (22226 & 22227).
2 6 . Reconnect the factory wiring harness main connector and both fog lights.
2 7 . Note: if your truck is not equipped with sensors, use the provided 1-1/4” plastic sensor plugs to fill the sensor holes (50250-HW).
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 AND OPERATION CAN RESULT IN SERIOUS INJURY OR EQUIPMENT DAMAGE. READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND OPERATING INSTRUCTIONS BEFORE INSTALLING AND OPERATING THIS PRODUCT.
110912-4
©2019 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
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