Warn 73040 Installation Instructions Manual

Warn 73040 Installation Instructions Manual

Heavy duty winch bumper

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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.
Failure to observe these instructions could lead to severe injury or death.
Always Read the Winch Operator's Manual and all warning labels before operating.
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:
Across any sharp edges.
o
Through or near moving parts.
o
Near parts that become hot.
o
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 replace all worn or damaged parts before operating.
Never operate this WARN product with damaged or missing parts.
Always refer to the Installation and Specification Guide, supplied in the winch kit, for all wiring
schematics and specific details on how to wire this WARN product to your vehicle.
NOTES
This bumper is not compatible with the factory optional front skid plate. Optional skid plate must be
removed for bumper installation.
WARN INDUSTRIES
INSTALLATION INSTRUCTIONS
HEAVY DUTY WINCH BUMPER
Application: 2007 TOYOTA FJ CRUISER
INJURY HAZARD
Notice
Equipment Damage
Read installation and operating instructions thoroughly.
Part Number: 73040
WARNING
PAGE 1
73465 A2

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Summary of Contents for Warn 73040

  • Page 1 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.
  • Page 2: Parts List

    11/16” socket and end wrenches 12mm socket 3/4” socket and end wrenches 14mm socket Flat blade screw driver 17mm socket 1/4 and 1/2” drill 7/16” socket and end wrenches Safety glasses 5/8” socket and end wrenches WARN INDUSTRIES PAGE 2 73465 A2...
  • Page 3: Torque Specifications

    Figure 2 Bumper mounting screws, left side 2. Remove the eight screws along the bottom of the bumper. Figure 3 Remove 8 screws in bottom of bumper (4 per side) Figure 3 Lower bumper mounting screws WARN INDUSTRIES PAGE 3 73465 A2...
  • Page 4 Figure 5 Lift center pin then pry fastener out Figure 5 Left grille fastener removal 5. Pull the grille free of the retaining clips with a “sharp” pull. WARN INDUSTRIES PAGE 4 73465 A2...
  • Page 5 7. Pull the bumper corners free by pulling the ends rearward and out. The top of the bumper is snapped into plastic clips just below the fender corners, in front of the flares. Pull the bumper free. Figure 7 Figure 7 Left bumper end removal WARN INDUSTRIES PAGE 5 73465 A2...
  • Page 6 Figure 8 LH bumper mounting block 9. Remove the three screws and remove the upper bumper support. Figure 9 Upper bumper support Remove 3 screws Do not remove the nuts on top Figure 9 Upper bumper support WARN INDUSTRIES PAGE 6 73465 A2...
  • Page 7 Remove 4 fasteners to remove skid pan Figure 11 Skid pan 12. Remove the molded plastic inner fender extensions by clipping or drilling out the rivets holding them to the bottom of the inner fenders. Figure 12 WARN INDUSTRIES PAGE 7 73465 A2...
  • Page 8 13. Hold a Frame Bracket in position and insert a 12mm bolt with 1/2” lock washer and flat washer through the bottom hole in the Bracket and into the threaded hole in the frame. Do not tighten yet. Figure 14 WARN INDUSTRIES PAGE 8...
  • Page 9 17. Locate the left outer hole in the bottom of the front cross member. This is threaded and some vehicles have a transmission cooler-line bracket bolted into it. Remove the bolt if equipped, and carefully enlarge WARN INDUSTRIES PAGE 9...
  • Page 10 Bracket and cross member. Install a 1/2” flat washer, lock washer and nut. Do not tighten yet. Figure 17 RH Cross Member Bracket Figure 17 RH Cross Member bracket installed WARN INDUSTRIES PAGE 10 73465 A2...
  • Page 11 27. The plastic inner fenders can be tucked up into the rear of the bumper and zip-tied to the body mount studs or trimmed to the desired shape. Figure 19 28. Reinstall the skid pan and grille with the original fasteners. WARN INDUSTRIES PAGE 11 73465 A2...
  • Page 12 (2) 7/16” bolt lock washer hex nut Figure 20 RH Light Bracket installed Install the License Plate “L” Brackets using the 1/4” hardware. The brackets can be installed from the back of the bumper. Figure 22 WARN INDUSTRIES PAGE 12 73465 A2...
  • Page 13: Maintenance & Care

    WARNING PERFORM REGULAR INSPECTIONS ON THE WINCH, BUMPER, AND RELATED HARDWARE. NEVER OPERATE THE WINCH WITH DAMAGED OR MISSING PARTS. FAILURE TO FOLLOW THIS WARNING MAY CAUSE VEHICLE DAMAGE AND OPERATOR INJURY OR DEATH. WARN INDUSTRIES PAGE 13 73465 A2...

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