INSTALLATION INSTRUCTIONS ELITE FRONT BUMPER Part Number: 87750 w/ Grille Guard & 87775 w/o Grille Guard Application: Jeep JK 2007+
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. 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 special attention. 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
1
87926A7
CAU T 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.
NOT I CE 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.
N O T E S
The Warn Elite Bumper for the Jeep JK will accept a large range of mid frame winches with up to 12,000 lb. capacities. The Bumper has been designed to accommodate the standard 4-1/2 x 10” feet down mounting pattern as well as the 4-1/2 x 6” short drum pattern. The Warn PowerPlant HP and HD can be installed using the offset mounting holes and included Offset Fairlead Plate.
BEFORE YOU BEGIN
• The Elite Bumper is designed to accept a wide variety of mid frame winches. Standard 4-1/2” x 10”, 4-1/2” x 6” short drum and 4-1/2” x 10” offset mounting holes are available. Some winches mounted in some locations may require sheet metal trimming. The Warn PowerPlant must be mounted in the offset position and will require trimming of the top of the Jeep bumper mounting plate. The Warn 9.5ti and 9.5cti mounted in the center position will require trimming of the plate but will require no trimming in the offset position. The Warn ZEON must be mounted in the center position and will require trimming of both mounting plates. • Models equipped with factory fog lamps will need to have the wires lengthened before installing in the outboard locations in the Elite Bumper. Additional wire and connectors are included in this kit as well as special brackets for installing factory fog lamps. • 2012 Jeep JK’s are equipped with a canister mounted to the inside of the driver side frame rail, behind the bumper. This must be relocated and the metal bracket trimmed before bumper installation. Instructions on how to do this are included. • The Elite Bumper is not compatible with the factory skid plate. It will not be reinstalled after installation of the WARN Elite Bum - per
TABLE OF CONTENTS Tools Required.......................................................................................................page 2 Torque Specifications ............................................................................................page 2 Parts List ................................................................................................................page 3 Installation .......................................................................................................page 4-10
TOOLS REQUIRED
- Ratchet, extensions, universal - Sockets: 10mm, 18mm, 7/16”, 5/8”, 11/16”, 15/16” - End Wrenches: 10mm, 3/16”, 7/16”, 5/8”, 11/16” - Phillips Screwdriver, metal cutting saw
TORQUE SPECIFICATIONS
1/4 8 lb. ft. (10.8 N-m) 5/16 17 lb. ft. (12.5 N-m) 3/8 30 lb. ft. (40.7 N-m) 7/16 50 lb. ft. (67.8 N-m) 1/2 75 lb. ft. (101.7 N-m)
2
87926A7
PARTS LIST
QTY
NAME
PART # 87530 87526 87527 87528 87529 87531 87927 87998 93841 87371 87928 88043 87611
1 1 1 1 1 2 1 2 1 2 1 2 1
ELITE BUMPER W/GRILLE GUARD
FAIRLEAD PLATE, STD FAIRLEAD PLATE OFFSET FOG LAMP BEZEL, LH FOG LAMP BEZEL, RH LIGHT MOUNT BRACKET
HRDWR KIT
LIGHT INSERT TUBE
CANISTER RELOCATION BRACKET
SUPPORT BRACKET
HARNESS EXTENSION KIT FACTORY FOG LAMP BRACKET ELITE BUMPER W/O GRILLE GUARD
3
87926A7
INSTALLATION INSTRUCTIONS
FOG LAMP BEZEL AND LIGHT INSERT TUBE INSTALLATION
The view shown is the back of the driver’s side of the bumper. In this illustration, you are shown the light insert tube location. It is attached with the same hardware that attaches the left and right hand fog lamp bezels and places the metal bumper face between the two. The same light insert tube fits both the left and right hand side of the bumper. Notice the (L) and the (R) embossed in the plastic on insert tube. Attach the plastic inserts tube using the hole nearest the (L) at the location shown at the same time you are installing the fog lamp bezel. Repeat the installation on the passenger side of the bumper using the hole next to the letter (R).
4
87926A7
INSTALLATION INSTRUCTIONS
1. Remove skid plate by removing 6 plastic fasteners, 4 across the bottom of the bumper and 1 behind each end of the blocker beam. Figures 2 and 3.
Plastic skid plate fasteners
Figure 2
Plastic skid plate fasteners
Figure 3
2. Unplug the factory fog lamps if equipped. Detach the wire harness from the bumper. Figure 4.
Pump/canister
Figure 4
5
87926A7
INSTALLATION INSTRUCTIONS
3. Remove the 8 nuts (4 each side) that secure the bumper to the frame ends. Access from behind the bumper.
Trim brackets
4. Remove the trim panel from the top of the frame by remov - ing the 2 plastic fasteners.
Figure 5
5. Extend the fog lamp harness wires. The fog lamp loca - tions in the Elite Bumper are farther apart than the factory locations. The harness must be lengthened to reach the openings. Only the driver side harness needs to be ex - tended. Cut both fog lamp wires 4-6” in from the plug on driver side. Strip ¼” of insulation from each wire, both at the harness end and the plug end. Use the supplied wires and crimp type butt connectors to extend the fog lamp har - ness. Cover the extension with the corrugated wire loom provided.
Figure 6
NOTE: If vehicle is not equipped with a vacuum canister mounted to the inside of the driver side frame rail (2012 model year), skip steps 6-8.
6. Remove the canister from the inside of the driver side frame rail if equipped. Trim left and right canister brackets as shown in Figure 5. Use a hacksaw or reciprocating saw with metal blade. Be careful not to damage any lines or wires. Touch up raw edge with paint to prevent rust. Figure 6.
Figure 7
7. Carefully disconnect the hoses and electrical connection. Be careful not to strain or kink the lines, wires, or fittings. Figure 7.
Enlarge slot
8. Use a grinder or file to enlarge the slot in the factory canis - ter bracket to match the frame hole behind it, about 5/8” diameter. Figure 8. Touch up raw edge with paint to prevent rust. Figure 9.
Figure 8
6
87926A7
INSTALLATION INSTRUCTIONS
Figure 9
9. If you are installing a PowerPlant, 9.5ti or 9.5cti trim the top flange of the passenger side bumper mount. Figure 10.
Trim for some applications
Figure 10
If you are installing a ZEON trim the top flange of the driver and passenger side bumper mounts. Figure 11 and 12.
Figure 11
Figure 12
7
87926A7
INSTALLATION INSTRUCTIONS
10. Bolt the Canister Relocation Bracket to the support bracket using 1/4-20-1” capscrews. Do not fully tighten yet. See Figure 13.
Canister bracket installed
Figure 13
11. Install the Support Brackets. The brackets are the same. Use 5/8 X 1-1/2” bolts and flat washers through the rear slot for driver’s side and front slot for passenger’s side. Use the 5/8” nut plates inside the frame. Figure 14. Position them as shown in Figures 15. Do not tighten yet.
Nut plate
Figure 14
Frame bracket installed
Figure 15
12. Install the bumper using 8 each (4 per side) 7/16 x 1-1/4” capscrews with flat washers and lock washers through the back of the frame pads into the bumper. Install 2 ( 1 per side) 7/16 nuts and washers on the top-outside bolts. Figure 16.
Figure 16
8
87926A7
INSTALLATION INSTRUCTIONS
13. Attach the Frame Brackets to the Bumper with 2 each 7/16 x 1-1/4” capscrews and flat washers, lock washers and hex nuts per side. Do not tighten yet. Figure 17.
14. Attach the vacuum canister to the Relocation Bracket with the (2) 6mm capscrews and flat washers provided. Use the 6mm flange bolts, lock nuts and washers to secure it. Make sure the canister, hoses, fittings and wires are not strained, kinked, pinched or rubbing against any moving parts. Use wire ties as needed. Figure 17. 15. Tighten the hardware to the correct specifications. Tighten the 8 Bumper mounting bolts, the 4 Frame Bracket to Bumper bolts then the 5/8” Frame Bracket to Frame bolts. Next, tighten the Canister Relocation Bracket then the canister (if equipped).
Figure 17
16. Install the fairlead plate with the cut out corners pointing down. Use the centered plate if the winch will be mounted using the centered hole patters. Use the offset plate if the winch will be mounted using the offset hole pattern. DO NOT MIX THE PLATES. Using the incorrect plate can damage the winch and/or winch rope. Figure 18.
a. Install the fairlead, use the 7/16 x 1-1/4 capscrews, flat washers, lock washers and nuts to secure the fairlead plate. Install the capscrews from the rear to avoid interference with the winch. Use the hardware that came with the fairlead to attach the fairlead.
Figure 18
17. Install the winch. Select the best mounting hole pattern. . NOTE: The motor ground cable may need to be rotated at the motor to avoid interfering with the frame bracket bolts. Figure 20. Use the hardware supplied with the winch. Tighten to the torque specification supplied with the winch.
Figure 19
Canister bracket installed
18. Two holes are provided in the Bumper face for license plate installation.
Rotate ground cable to this position
19. Remove the factory fog lamps from the factory bumper by removing the 4 Phillips screws around each lamp. Figure 20.
Figure 20
9
87926A7
20. Enlarge each fog lamp mounting hole to 1/4”.
Remove screws and enlarge holes
21. Attach the fog lamps to the Fog Lamp Brackets using the 1/4-20 x 1” capscrews, flat washers and lock nuts. Make sure the fog lamp vents are on top. Figure 21.
22. Install the left and right Fog Lamp Bezels. Use 6 each 8-32 x .75 hex socket screws for each bezel. Install flat washers and lock nuts on the back of the bumper and tighten. These fasteners need only to be snug. Do not over tighten.
23. Install the fog lamps and Brackets. Use 7/16 x 1-1/2” capscrews, flat washers, lock washers and nuts. Adjust lamps and tighten. Figure 21.
Figure 21
24. Reconnect the fog lamp wires to the lamps. Secure the fog lamp wires with wire ties.
NOTE: Non-Factory Auxiliary Lights: Many 4” or smaller after- market fog and driving lamps can be used in the light ports if they can be mounted with the stem to the side. Check with the manufacture of the light to make sure they can be used in this way. Mount directly to the slots in the bumper gussets. If the light stems are too short use the supplied Light Mount Brackets. If you use the Light Mount Brackets use 7/16 x 1-1/4 cap- screws, nuts and flat and lock washers for the bracket. WARN has a number of auxiliary light options that work in this application. Call Warn Customer Service or check online for a list of current available models. NOTE: Four extra 7/16” washers are supplied with the hard- ware kit. These are intended to aid in centering non factory auxiliary lights including Warn W350F.
Figure 22
Figure 23
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.
10
87926A7
Page 1 Page 2 Page 3 Page 4 Page 5 Page 6 Page 7 Page 8 Page 9 Page 10Powered by FlippingBook