107226.A0-install-instr-ascent-hd-front

INSTALLATION INSTRUCTIONS Ascent-HD Front Bumper Part Number: 10700X Application: 2019+ Dodge Ram 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

107226A0

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 4-13 Maintenance/Care ........................................................................................ ..page 14

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

- Standard wrenches - Standard sockets - Metric socket set

- 3/4” 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"

(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”

107226A0

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

PARTS LIST

ITEM PART NO. DESCRIPTION

QTY

ITEM

PART NO. 22256-W

DESCRIPTION

QTY

10700X

WARN Ascent HD 2019-20Dodge Ram HD Bumper

6.2

10700X PS mounting bracket

2.1 2.2

94888 94889 102483 101064 101065 101072 101067

Light Insert RH Light Insert LH

1 1 1 1

3 4

WARN Ascent DS Label

50249-HW WARN Dodge Ram HD 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 (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

100601 100604 100606 100624 100638 20296 22255-W

8 8 8 6 6 4 1

½ Flat washer

1 3/8 Rubber grommet

Plastic plug ½” Bolt strip

6.1

10700X DS mounting bracket

A12

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. Disconnect the IBS sensor connection from sensor on the negative battery terminal. (Fig. 1, #1)

2. Using a 10mm socket wrench, disconnect the negative terminal from the battery. (Fig. 1, #2)

(Figure 1)

3. If applicable, disconnect the negative terminal from the auxiliary battery. (Fig. 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

** Note: Driver side shown and passenger side disassembly process is similar**

4. Using an 8mm Socket wrench and plastic panel pry tool, remove the two (2) screws and one (1) push pin from the rear splash shield trim. (Fig. 3)

(Figure 3)

5. Using an 10mm socket wrench and plastic panel pry tool, remove the twelve (12) screws and two (2) push pins from the inner fender and set aside for trimming. (Fig. 4 - 5)

(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

(Figure 5)

6. Disconnect the factory wiring harness from the inside of the driver side wheel well (Fig. 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. With assistance, support the bumper from both sides of the vehicle. Using an 18mm socket wrench, 24mm socket wrench and 18mm open end wrench, remove the three factory bumper bolts that hold the factory bumper to the frame rail. (Fig. 7)

(Figure 7)

8. **Note: The factory tow hooks stay in the frame rail while extracting the front bumper from the rail ends**

9. Remove the factory bumper from the vehicle and set aside. (Fig. 8)

(Figure 8)

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. Using a 24mm socket wrench, remove the factory bolt and nut tabs from the frame rail to remove the factory tow hooks and crash bars. (Fig. 9)

(Figure 9)

11. Remove the factory tow hooks.

12. Unclip the factory wiring harness from the six (6) front sensors and two (2) fog lights.

13. Remove the sensor from the sensor housing by expanding both sides of the sensor housing and lifting up. (Fig. 10-11)

(Figure 10)

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 11)

14. Remove the sensor housing from the bumper by depressing the four (4) tabs while pulling outward from the outside of the bumper. (Fig. 12-13)

(Figure 12)

(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

15. Using a plastic panel pry tool, begin removing the factory wiring harness from the factory bumper by unclipping the various push pins. (Fig. 14-15)

(Figure 14)

(Figure 15)

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. Remove the factory wiring harness and set aside. (Fig. 16)

(Figure 16)

17. 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.)

18. Use the OEM hardware removed during steps 7 and 9 to install the mounting brackets (22255-22256). (Fig. 17)

(Figure 17)

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 epoxy, secure all six (6) OEM sensor housings in their appropriate sensor cutout in the bumper. (Fig. 18)

**Note: If you do not have sensors you will insert the grommets supplied in the hardware kit**

(Figure 18)

20. After the epoxy has cured, fully seat all six (6) 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.

21. Route and zip tie the factory wiring harness to the bumper with the main factory connector being on the passenger wing.

22. Install the provided light inserts (94888 and 94889) using the #10 hardware along with a 10mm wrench and 3mm Allen wrench. (Fig. 19).

(Figure 19)

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

23. With assistance hold the bumper up to the mounting brackets and use the provided (4) 1/2” Bolt strips (20296) with the 1/2" zinc nuts and washers to attach the bumper with a 3/4” socket wrench (50235-HW). (Fig. 20)

(Figure 20)

24. Align bumper as desired and fully tighten all mounting hardware.

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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