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INSTALLATION INSTRUCTIONS ASCENT FRONT BUMPER Part Number: 110759 AND 110760 Application: 2023 Ford Super Duty

GENERAL SAFETY PRECAUTIONS

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. 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 special attention. CAUTION

WARN I NG IMPACT AND MOVING PARTS ENTANGLEMENT HAZARD Failure to observe these instructions could lead to severe injury or death

• Always Know Your Winch. Take time to fully read the Instructions and/or Operations Guide, and/or Basic Guide to Winching Techniques, in order to understand your winch and its operations. • 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 extreme caution when drilling on any vehicle. Make sure that all fuel lines, brake lines, electrical wires, and other objects are not punctured or damaged when / if drilling on the vehicle. Thoroughly inspect the 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 Sales/Customer Service: 1-503-722-3008 International Fax: 1-503-722-3005

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CAUT I ON

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.

EQUIPMENT DAMAGE NOT I C E

•

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.

BEFORE YOU BEGIN

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.

TOOLS REQUIRED

• PANEL PRY TOOL • TAPE MEASURE • SILVER MARKER

• 11MM SOCKET WRENCH • 15MM SOCKET WRENCH • 18MM SOCKET WRENCH • 7/16” SOCKET WRENCH • 7/16” COMBINATION WRENCH • 3/4” COMBINATION WRENCH • 3/4” DEEP SOCKET WRENCH

• DRILL

• 5/16” DRILL BIT • E6 TORX SOCKET

• 1/8” ALLEN WRENCH • 8MM SOCKET WRENCH

TORQUE SPECIFICATIONS

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) M4 (2) 3 5/16" 17 (23) M5 (4.5) 6 3/8" 30 (40) M6 (7.5) 10 7/16” 48 (66) M8 (18) 25 1/2" 74 (100) M10 (37) 50 9/16” 106 (144) 5/8" 148 (200) 3/4” 269 (364)

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PARTS LIST

Item QtyName A1 1 BUMPER

Item QtyName B1 20 10-24 X 3/4" BOLT - SS B2 20 10-24 NUT B3 20 #10 LOCK WASHER B4 20 #10 FLAT WASHER B5 2 1/4"-20 X 1.00" BOLT B6 2 1/4"-20 NUT B7 4 1/4" FLAT WASHER B8 2 10-24 X 3/4" BOLT - BLACK B9 2 10-24 CLIP-ON NUT B10 4 1/2"-13 x 2.00" BOLT B11 16 1/2" LOCK WASHER B12 20 1/2" FLAT WASHER B13 16 1/2"-13 NUT B14 6 1/2" BOLT RETAINER B15 4 1-3/8" PLASTIC GROMMET B16 4 PLASTIC PLUG

A2 1 ACC SENSOR MOUNT A3 1 LH FRAME MOUNT A4 1 RH FRAME MOUNT A5 6 1/2” BOLT STRIP A6 2 EPOXY A7 1 ACC FILLER PANEL A8 1 WARN LH LIGHT PORT A9 1 WARN RH LIGHT PORT

B13

B11

B12

B14

B11

B13

B10

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INSTALLATION INSTRUCTIONS

1. Remove the plastic tow hook covers by gently pulling on them to release the clips.

5. Using an E6 torx socket remove the three studs that attach the ACC bracket to the vehicle.

2. From the driver side frame rail, disconnect the bumper electrical harness.

6. Using an 18mm socket wrench, remove the four bolts that attach the bumper to the tow hook brackets (each side).

3. If applicable, remove the adaptive cruise control (ACC) sensor from its mounting bracket.

7. Using a 15mm socket wrench, remove the two bolts that attach the bumper reinforcement brackets to the frame (each side).

4. If applicable, disconnect the electrical connector from the ACC sensor.

8. Using a body panel pry tool, remove the push pin attaching the shroud to the grille (each side). Remove bumper from the vehicle.

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INSTALLATION INSTRUCTIONS

9. Using an 18mm socket wrench, remove the four bolts attaching the tow hook to the frame (each side). Remove the tow hooks.

12. From the inside of the stock bumper, use a panel pry tool to remove the push pin clips.

13. If equipped, remove the parking sensors from the housings. NOTE: Be sure to mark the location (LH/ RH, Inner/Outer) and orientation (Top/Bottom) of each sensor. TIP: Numbering each sensor with tape and marking with a paint pen works well. 14. Remove the sensor housing from stock bumper. NOTE: Be sure to mark the location (LH/RH, Inner/ Outer) and orientation (Top/Bottom) of each sensor carriage.

10. Using an 18mm socket wrench, remove the four nuts attaching the underrun guards to the bottom of each frame rail (each side). Retain for later reinstall.

Park Sensor Harness

Sensor

Sensor Housing

11. Using an 8mm socket wrench, remove the four screws in each fog light bracket to remove them from the bumper.

For illustration purposes only

15. Install the left and right frame mounts (A3/A4) using two 1/2”-13 bolts (B10) four flat washers (B12), two lock washers (B11) and two nuts (B13). Refer to exploded view on page 3. 16. Reinstall underrun guard bolt strips that were removed in Step 10.

Bolt Strips

A4, B10, B11, B12 & B13

A3, B10, B11, B12 & B13

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INSTALLATION INSTRUCTIONS

17. While holding light port (A8 or A9) in place, secure with ten stainless screws (B1), lock washers (B3), flat washers (B4) and nuts (B2). Repeat for other side. Review exploded view on page 3.

20. Apply the provided epoxy on the inside of the bumper around the sensor housing to hold them in place.

18. Install three 1/2” bolt strips (A5) into the inside of the bumper mounts and secure them in place using the bolt retainers (B14). Repeat for other side. TIP: Using a 3/4” deep socket can assist in pushing the retainers flush against the mount.

21. Find the protective filler panel (A7) for the ACC sensor. With the smooth side facing up against the bumper wall of the opening of the bumper, trace the bumper opening and mark the two screw holes.

22. Using a tab measure, mark an offset line to the previously marked line, by 5/8 inch. 23. Using a knife, cut along the offset line. 24. Use a 5/16” drill bit to drill out the two marked holes in the panel.

19. If vehicle is equipped with parking sensors, reinstall the parking sensor housings and sensors into their respective locations and orientations. If vehicle is not equipped with parking sensors, install the provided rubber grommets (B15) and plastic plugs (B16) into the cutouts.

Drill Hole

Sensor Plug

Offset Line

Park Sensor Harness

Sensor

Offset Line

16ths

Sensor Housing

1 2 3 4 5

For illustration purposes only

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INSTALLATION INSTRUCTIONS

25. Place the clip nuts (B9) on the trimmed filler panel, aligning holes.

29. If installing a winch/fairlead, do so now following the winch manufacture’s instructions provided with the winch.

CAUTION Always use assistance when moving or lifting heavy parts.

26. Install the ACC filler panel to the inside of the bumper using the two black 10-24 screws (B8). NOTE: The ACC sensor can be adjusted for calibration after the bumper is installed by removing the filler panel to access the top stock stud.

30. With assistance, lift the new bumper in position and slide the strip bolts into the mounting holes on each frame bracket. 31. Loosely secure the bumper with the 1/2”-13 nuts (B13) onto the bolts to hold the bumper in place. 32. Align the bumper into the correct position (center left and right), and then fully torque down the hardware. TIP: Tighten the bolts into the truck frame first and then the nuts on the strip bolts.

27. Install the ACC sensor to the new ACC mount (A2) provided in this kit, using the factory ACC bolts.

33. Reconnect ALL wiring harnesses.

34. Complete your winch wiring installation following your winch installation instructions.

35. Confirm all hardware is has been tightened to recommended torque.

28. Install ACC sensor mount to bumper using the 1/4”-20 bolts (B5), flat washers (B7) and nuts (B6). NOTE: the OE bolts may interfere with the winch. If this is the case, slight trimming of the bolt length may be necessary to provided clearance.

Installation is now complete

B5, B6, B7

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MAINTENANCE / CARE 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 UNDER- STAND ALL SAFETY PRECAUTIONS AND OPERATING INSTRUCTIONS BEFORE INSTALLING AND OPERATING THIS PRODUCT.

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