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Warn 96550 Installation Instructions Manual

Warn 96550 Installation Instructions Manual

Ascent rear bumper, application: 2015+ chevrolet 1500, 2500 and 3500

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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.
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.
• 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.
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
©2015 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
INSTALLATION INSTRUCTIONS
ASCENT REAR BUMPER
Application: 2015+ Chevrolet 1500, 2500 and 3500
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: 96550
1
CAUTION
96551A2

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Summary of Contents for Warn 96550

  • 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

    EQUIPMENT DAMAGE • 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. Read installation and operating instructions thoroughly. B E F O R E Y O U B E G I N...
  • Page 3: Parts List

    3/8-16 X 1.5 HEX HEAD BOLT 11524 3/8 FLAT WASHERS 6779 3/8 LOCK NUTS 13231 BLACK ZIP TIES 69427 FLAT WASHER 98180 NUT ASSEMBLY 96551A2 ©2015 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 4: Removal Of The Oem Bumper For The 1500

    Unplug license plate light wire harness and back up sensors (if equipped). NOTICE Be careful when removing sensors and sensor retainer from bumper as to not damage Figure 3 96551A2 ©2015 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 5 Remove bolt Figure 5 Frame Bolt Frame Nuts Remove the two frame nuts and the one frame bolt (each side). Figure 6. Figure 6 96551A2 ©2015 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 6 7. Repeat for each side. Go to page 10 for your WARN Bumper installation instructions. Figure 9 96551A2 ©2015 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 7: Removal Of The Oem Bumper For The 2500 And 3500

    Figure 3 96551A2 ©2015 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 8 Un-bolt the box’s rear bolts. You will need an extension to reach the bolt. 10. Repeat steps for other side. Box/Bed rear bolt Figure 6 96551A2 ©2015 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 9 C A U T I O N • Always use assistance when moving or lifting heavy parts. Go to page 10 for your WARN Bumper installation instructions. 96551A2 ©2015 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 10 Using a pick, bend each prong back and out of way. Take care, bending prongs as to not damage because you will be reusing in new bumper. Figure 3 96551A2 ©2015 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 11 Carefully bend prongs back in place on the inner ring and reinstall in new bumper. See Figure 6 and 7. Figure 6 Figure 7 96551A2 ©2015 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 12 10. Insert trailer harness receptacle into new bumper. Figure 9 11. Insert one u-clip nut (B2) over lower tab on license plate lamp weldment. u-clip Figure 10 96551A2 ©2015 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 13 NOTE: If your vehicle did not come equipped with rear sensors, use the supplied plugs to cover sensor locations. Figure 13 96551A2 ©2015 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 14: Maintenance/Care

    Check all cables prior to use. Replace cables that look worn or frayed. Check all moving or rotating parts. Remove debris that may inhibit the part from moving freely. 96551A2 ©2015 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.