14-102877A0-install-instr-semi-hidden-winch

INSTALLATION INSTRUCTIONS SEMI-HIDDEN WINCH INSTALL Part Number: 102876 Application: 2005-2011 Toyota Tacoma

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 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. • 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 wear safety glasses when installing this kit. A drilling operation will cause flying metal chips. Flying chips can cause eye injury. • Always use extreme caution when cutting and trimming during fitting.

• Always remove jewelry and wear eye protection. • Never lean over battery while making connections. • Never route electrical cables: o Across any sharp edges.

o Through or near moving parts. o Near parts that become hot.

• Always insulate and protect all exposed wiring and electrical terminals. • Always install terminal boots as directed in installation instructions. • 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 instructions. • Always perform regular inspections and maintenance on the plow mechanism, fasteners, cable and related hardware.

• Always replace all worn or damaged parts before operating. • Never operate this WARN product with damaged or missing parts.

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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CAUT I ON MOVING PARTS ENTANGLEMENT HAZARD Failure to observe these instructions could lead to minor or moderate injury

• Always take time to fully read and understand the installation and Operations Guide included with this product. • Never operate this product if you are under 16 years of age. • Never operate this product when under the influence of drugs, alcohol or medications.

Read installation and operating instructions thoroughly.

NOT I C E EQUIPMENT DAMAGE

•

Never tow vehicle by attaching a tow bar to the eyelets on the bumper.

• Never 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.

NOT I C E

This product may interfere with driver assist systems such as adaptive cruise control and parking as- sist 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.

TABLE OF CONTENTS Tools Required.............................................................................................................................page 2 Torque Specifications................................................................................................................page 2 Maintenance/Care......................................................................................................................page 2 Parts List.........................................................................................................................................page 3 Installation..............................................................................................................................page 4-11

TOOLS REQUIRED

- Standard and Metric wrenches - Standard and Metric sockets

TORQUE SPECIFICATIONS Please use the recommended torque specifications when assembling this product unless otherwise specified in the instructions.

MAINTENANCE / CARE 1. Inspect all parts on the winch, winch mount, and related hardware prior to each use. Replace all hardware that ap- pears 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 ap- pear to be loose. Stripped, fractured, or bent bolts or nuts need to be replaced.

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

3. Check all cables prior to use. Replace cables that look worn or frayed.

7/16”

1/2"

(100) (144) (200) (364)

M10

4. Check all moving or rotating parts. Remove debris that may inhibit the part from moving freely.

9/16”

106 148 269

5/8" 3/4”

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PARTS LIST

ITEM PART NUMBER

DESCRIPTION

QTY

A1 A2 A3 A4 A5

102448 102385

SEMI HIDDEN WINCH MOUNT FRAME BRACKET STRAP FLANGE BOLT M10X35-1.25 FLANGE BOLT M6X25-1.00 FLANGED NUT HEX M6X1.0

1 2 4 2 2

91164 64108 83125

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INSTALLATION INSTRUCTIONS

1. Remove the two screws at the top edge of the grille using a 10mm socket.

2. Remove the two push pins at the outer corners of the grille.

3. Pull the grille straight up, being careful to not break the clips located at the bottom corners of the grille.

4. Unplug fog lights by squeezing the locking tab socket. Repeat for other side.

Figure 1

NOTE: If equipped, unplug parking sensor.

Figure 2

5. Remove the three top bumper plastic push pins.

Figure 3

6. Remove the two bumper cover bottom center screws.

Figure 4

7. Remove the two bumper cover corner screws (each side).

Figure 5

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8. Remove the ¼-turn fastener (each side) using a wide slotted screwdriver and turning 90° counter clockwise.

Figure 6

9. Remove the screw using a 10mm socket. NOTE: The screw is not visible and must be reached through an existing cutout in the wheel well liner.

Figure 7

10. If equipped, the skid plate on TRD models will need to be loosened and lowered by removing the two center bolts with a 12mm socket.

Figure 8

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11. Remove the push pin on outer corner of headlight finisher panel (each side).

Figure 9

12. Pull the finisher panel firmly towards the center of the vehicle and carefully remove. Repeat for other side.

Figure 10

13. With the headlight finisher removed on each side, firmly grasp the bumper cover at the wheel well and pull firmly out until both internal clips have released.

14. Repeat for other side.

15. Carefully remove bumper cover and set face down on a padded surface

Figure 11

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16. Using a deep 14mm socket, remove the 6 nuts holding the crash bar to the frame extensions. Save nuts to be reused later.

Figure 12

17. With the crash bar removed, use a 14mm deep socket to remove the six nuts securing the frame extensions. Save nuts to be reused later. These nuts will be reused in the mounting of the new kit.

Figure 13

18. Remove frame extension.

19. With the bumper cover on a stable surface, it can now be modified to fit the new kit.

Figure 14

20. Using a pneumatic reciprocating saw or other suitable tool, cut along the lines shown. Be sure to cut inside the body lines to leave as much of the original plastic intact as possible. Be careful to not damage the paint on other areas of the bumper cover. NOTE: It may be helpful to mask the areas near around the cuts to prevent damage during modification and installation.

Figure 15

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21. Reinstall bumper cover.

Figure 16

22. Firmly snap in the locking tabs at the upper corners of the bumper cover in front of the wheel well.

Figure 17

23. Reinstall the ¼ turn fasteners by inserting and turning 90° clockwise with a wide slotted screwdriver. Repeat for other side.

Figure 18

24. Carefully insert and thread the screw through the cutout in the wheel well liner. Repeat for other side.

Figure 19

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25. Reinstall the two bumper cover corner screws (each side).

Figure 20

26. Reinstall the headlight finisher trim pieces beneath the headlight by sliding the locking tab into the slot. Repeat for other side.

Figure 21

27. Reinstall the plastic push pin into position. Repeat for other side.

Figure 22

28. If equipped, plug in fog lights and parking sensors (both sides).

Figure 23

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29. Reinstall the three top bumper plastic push pins.

For TRD models : First remove stock tow hooks on passenger side before installing winch kit.

Figure 24

30. Place winch inside new semi hidden winch mount (A1). NOTE: Lay winch on its side so it will fit inside vehicle. You flip upright as soon as bumper is on vehicle.

Figure 25

31. Install fairlead using instructions and hardware found in the winch kit.

32. With assistance, place mount on vehicle.

Figure 26

33. Flip winch upright.

34. Secure with six factory frame extension nuts (removed in step 16).

35. Secure and wire winch to mount and vehicle per winch installation instructions.

Figure 27

36. Install two bolts (A3) through top hole on mount.

Figure 28

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37. From underneath vehicle, install one factory nut (removed in step 15) on bolts (A3) installed above.

38. From underneath vehicle, remove factory frame bracket bolt and set aside.

39. Repeat for other side.

Figure 29

40. Install frame bracket strap (A2) and reinstall factory bolt in same position just removed.

A3 bolt and Factory nut

41. Install kit bolt (A3) in other hole and secure with one of the remaining factory nuts.

42. Repeat for other side.

Factory bolt

Figure 30

43. Reinstall grille.

44. Push the grille down into the locking tabs and slots located at the bottom corners.

Figure 31

45. Reinstall the outer push pins and center screws.

License mounting location

46. Install license plate with hardware included (A4 & A5).

Figure 32

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