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AEV Bison Installation Manual

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BISON WINCH KIT
FOR WARN 9.5 XPS WINCH
AEV30350AC
Last Updated: 09/06/19

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Summary of Contents for AEV Bison

  • Page 1 BISON WINCH KIT FOR WARN 9.5 XPS WINCH AEV30350AC Last Updated: 09/06/19...

  • Page 2: Please Read Before You Start

    These instructions assume a certain amount of mechanical ability and are not written nor intended for someone not familiar with auto repair. INCLUDED PARTS REQUIRED TOOLS Bison Winch Fairlead Common Hand Tools Controller Mount Bracket Wiring Harness...
  • Page 3 A M E R I C A N E X P E D I T I O N V E H I C L E S I. DISASSEMBLY Disconnect and isolate the negative battery cable. Remove Front Bumper Skid. Remove the 4 M4 torx screws attaching the license plate bracket (fig. 1). Remove the 2 M10 bolts in middle of Front Bumper Skid (fig.
  • Page 4 A M E R I C A N E X P E D I T I O N V E H I C L E S Remove the 6 M10 torx bolts attaching the center section of bumper (fig. 4). Remove the 12 push clips attaching the air diverter (fig.
  • Page 5 Remove 1 M6 bolt on radiator support and SAVE (fig. 8). 10. Un-clip radiator overflow hose (fig. 8). Figure 8 II. CONNECTING AEV WIRING HARNESS Open Warn winch controller by removing QTY 4 bolts on bottom corners of controller (fig. 9). Figure 9...
  • Page 6 Connect AEV leads. Yellow = A, Green = F1, Blue = F2 Isolate the small black motor ground wire inside the controller. Cut and splice in the new motor ground wire from the AEV harness. NOTE: Make sure the splice will be located within the winch controller enclosure when reassembled.

  • Page 7: Winch Installation

    A M E R I C A N E X P E D I T I O N V E H I C L E S III. WINCH INSTALLATION Set bracket into place in front of the airbox. Position the controller bracket in place and loosely install the radiator support bolts removed earlier (fig. 12). FRONT OF VEHCILE Figure 12 Install supplied bolt through the tab at the bottom of the bracket into the existing hole shown and...
  • Page 8 1/4”, and rotate it every two holes to the de- sired position. Reinstall the screws. Start 2 AEV supplied M10 x 4” bolts at the top of the winch. C. Start 2 WARN supplied M10 bolts at the bottom of the winch.
  • Page 9 A M E R I C A N E X P E D I T I O N V E H I C L E S Figure 16 Connect wiring to winch. Run the leads along the top side of the lower radiator support, securing with zip ties. Connect the motor leads to the proper studs using the color to letter guide.
  • Page 10 E X P E D I T I O N V E H I C L E S C. Attach ground wire. 10. Run the winch cable through the Bison fairlead and drop into place (fig. 20). Figure 20 11. Trimming the air diverter (fig. 21).
  • Page 11 A M E R I C A N E X P E D I T I O N V E H I C L E S 12. Reinstall Center section of bumper 13. Reinstall Wheel Liner Closeouts 14. Reinstall Skid 1B (fig. 3). 15.
  • Page 12 A M E R I C A N E X P E D I T I O N V E H I C L E S 19. Attached positive line to battery. 20. Route the negative lead alongside the battery and connect to the negative terminal (fig. 24). Figure 24 21.

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Bison winch kit