107227A0 - install-instr-ascent-hd-bumper

INSTALLATION INSTRUCTIONS Ascent-HD Front Bumper Part Number: 107004-6 Application: 2020 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. Taketimeto fullyreadtheInstructionsand/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 useextremecautionwhendrillingonanyvehicle.Makesurethatall fuellines,brakelines,electricalwires,andotherobjectsarenot puncturedordamagedwhen/ ifdrillingonthe vehicle.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

107227A0

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. • 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 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 4-15 Maintenance/Care ........................................................................................ ..page 16

T O O L S R E Q U I R E D

- Standard wrenches - Standard sockets - Metric socket set

- 7/16” Open End wrench - 3/4” Open End wrench - Metric wrench set

- Torque wrench

- Plyers

- T10 Star Head socket wrench

- Body pry tool

- Wire cutters

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"

(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”

107227A0

PARTS LIST

ITEM PART NO. DESCRIPTION

QTY

ITEM

PART NO.

DESCRIPTION ½” Bolt strip

QTY

107004-6

WARN Ascent HD 2020 Chevrolet Base

1 1 1 1 1

20296

4 1 1 1

2.1 2.2

94888 94889

Light Insert RH Light Insert LH

6.1 6.2 7

22226-W 22227-W 22251

107004-6 DS mount bracket 107004-6 PS mounting bracket Chevrolet backer strip

3 4

102483

WARN Ascent DS Label

50250-HW WARN HW Kit

4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9

101064 101065 101072 101067 100601 100604 100606 100571 100573 100560 100543 100547 100548 100536 61776

10-24X3/4 Button head bolt (not all shown)

20 20 20 20

10-24 Machine screw nut #10 Split lock washer #10 Flat washer ½” -13 Hex head nut ½” Lock washer

8 8 8 4 4 4 4 4 4 4 4

½” Flat washer

3/8” x16 x 1 Hex head cap screw

3/8” Flat washer 3/8” Lock washer

4.10 4.11 4.12 4.13 4.14 4.15

¼”-20 Hex nut ¼” Lock washer ¼” Flat washer ¼”-20 x1 Hex head cap screw 1-1/4” Plastic sensor plug

107227A0

I N S T A L L A T I O N I N S T R U C T I O N S

A12B6

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)

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)

Figure 2

I N S T A L L A T I O N I N S T R U C T I O N S

3. With the 7mm bolt removed use a body pry tool to remove the valance from the truck. (Figure 3)

Figure 3.

4. Use a 10mm socket wrench to remove the two (2) bolts at the base of the grill. (Figure 4)

Figure 4

I N S T A L L A T I O N I N S T R U C T I O N S

5. Use a body pry tool to remove the nine (9) push pins holding the grill cover. (Figure 5)

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)

Figure 6.

I N S T A L L A T I O N I N S T R U C T I O N S

7. Use a 10mm socket wrench to remove the four (4) bolts on the top of the grill. (Figure 7)

Figure 7

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)

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)

Figure 9

I N S T A L L A T I O N I N S T R U C T I O N S

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 and one on the bottom. The bumper can now be removed from the truck. (Figure 10-11)

Figure 10

Figure 11

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)

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)

Figure 13

I N S T A L L A T I O N I N S T R U C T I O N S

13. Use a 15mm socket wrench to take four (4) bolts holding the mounting plates and lower louvers to the frame horns. (Figure 14)

Figure 14

14. Disconnect the lower louvers from the mounting plates by using a 7mm socket wrench to remove the six (6) bolts. Set bolts aside for later use. (Figure 15)

Figure 15

15. With the louvers removed, use a cutting tool to remove the plugs on both sides. (Figure 16)

Figure 16

I N S T A L L A T I O N I N S T R U C T I O N S

16. 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 17)

Figure 17

17. 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 WARN bumper. (Figure 18)

Figure 18

I N S T A L L A T I O N I N S T R U C T I O N S

18. Remove the sensor housings from the bumper by pressing the retainer clips in on the sides and pushing the housing out. (Figure 19)

Figure 19

19. Install the two mounting brackets (22226 and 22227) using a 15mm and 18mm socket wrench and the OEM tow hook bolts and bracket bolts removed during steps 12-13. (Figure 20)

Figure 20

I N S T A L L A T I O N I N S T R U C T I O N S

20. Using the provided four (4) bolt stacks of ¼”-20 yellow zinc hex bolt, flat washers, lock washer, and hex nut, loosely install the factory louver system with a ½” socket wrench. (Figure 21) (50250-HW)

Figure 21

21. 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 22)

Figure 22

I N S T A L L A T I O N I N S T R U C T I O N S

22. 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 23)

Figure 23

23. Using the provided epoxy, secure all four (4) OEM sensor housings in their appropriate sensor cutout in the bumper (107004-6). (Figure 24)

Figure 24

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. 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. 25. Route and zip tie the factory wiring harness to the bumper (107004-6) with the main factory connector being on the passenger wing.

26. Install the light housings (94888-94889) into the bumper using the #10 stainless steel bolts, flat/lock washers and nuts (50250-HW). (Figure 26)

Figure 26

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.)

I N S T A L L A T I O N I N S T R U C T I O N S

27. 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 27-28) (50250-HW)

Figure 27

Figure 28

28. 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 (107004-6) to the brackets. (22226 & 22227)

29. Reconnect the factory wiring harness main connector and both fog lights (if equipped)

30. 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). (Figure 29)

Figure 29

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 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.

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