Warn 103638 Installation Instructions Manual

Warn 103638 Installation Instructions Manual

Ascent front bumper kit

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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.
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.
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.
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
©2019 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc.
INSTALLATION INSTRUCTIONS
ASCENT FRONT BUMPER KIT
Application: 2019 Dodge Ram 1500
G E N E R A L S A F E T Y P R E C A U T I O N S
W A R N I N G
IMPACT AND MOVING PARTS ENTANGLEMENT HAZARD
Failure to observe these instructions could lead to severe injury or death
Read installation and operating instructions thoroughly.
Part Number: 103638
1
CAUTION signals a
105968A0

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Summary of Contents for Warn 103638

  • 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: Table Of Contents

    • 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..
  • Page 3: Parts List

    FASTENER TORQUE lb-ft (N.m) lb-ft (N.m) 1/4" (11) 5/16" (23) (4.5) 3/8" (40) (7.5) 7/16” (66) (18) 1/2" (100) (37) 9/16” (144) 5/8" (200) 3/4” (364) 105968A0 ©2019 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 4 Slide fender line down and out. Figure 2 If equipped, unplug the wiring harness located in the front left corner of the bumper. Figure 3 105968A0 ©2019 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 5: Installation

    12mm socket (see Figure 5 and 6) . Unplug NOTE: The air dam will not be reinstalled with the new bumper. Figure 5 Remove nuts Figure 6 105968A0 ©2019 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 6 From the front of the bumper, carefully insert each sensor carriage into the correct mounting hole and snap into place. NOTE: Be sure sensors match the orientation of the stock bumper. Figure 10 105968A0 ©2019 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 7 Repeat for other side. 19. Tighten all bumper hardware now, refer to torque Figure 14 specifications on page 3. 105968A0 ©2019 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 8: Maintenance/Care

    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. 105968A0 ©2019 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 9 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. 105968A0 ©2019 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc.

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