Warn 98054 - User Manual

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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

INSTALLATION INSTRUCTIONS

Ascent Rear Bumper

Part Number: 98054

Application: 2016+ Toyota Tacoma

GENERAL SAFETY PRECAUTIONS

WARNING

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, re or personal injury.

• Always wear safety glasses when installing this kit. A drilling operation will cause ying metal chips. Flying chips can cause eye injury.

• Always use extreme caution when cutting and trimming during tting.

• 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.

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 identies 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.

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Summary

General Safety Precautions

WARNING: Impact and Moving Parts Entanglement Hazard

Failure to observe these instructions could lead to severe injury or death. Focuses on risks associated with moving parts.

Safety Notices

CAUTION: Moving Parts Entanglement Hazard

Failure to observe these instructions could lead to minor or moderate injury. Reinforces safety around moving parts.

NOTICE: Equipment Damage

Warns against improper use of the bumper, like towing, to prevent equipment damage.

NOTICE: Driver Assist System Interference

Product may interfere with vehicle's driver assist systems; consult owner's manual.

Tools and Specifications

Tools Required

Lists the necessary tools for installation, including standard wrenches and sockets.

Torque Specifications

Provides recommended torque values for various fastener sizes during assembly.

Installation Steps

Step 1-6: Bumper Removal Preparation

Instructions for removing the license plate, frame bracket bolts, trailer harness, and bumper.

Step 7-11: Bumper Bracket and Frame Preparation

Details on removing small bolts, plastic covers, and freeing the bumper from frame brackets for reinstallation.

Step 12-15: Component Transfer and Sensor Installation

Guidance on transferring bumper trim, lamps, trailer receptacle, and sensors to the new bumper.

Step 16-20: Bumper Mounting and Securing

Instructions for positioning the bumper, securing it with specific hardware, and tightening all connections.

Step 21-24: Final Assembly and Finishing

Steps for installing light bezels, license plate, and ensuring all components are secured.

Summary

General Safety Precautions

WARNING: Impact and Moving Parts Entanglement Hazard

Failure to observe these instructions could lead to severe injury or death. Focuses on risks associated with moving parts.

Safety Notices

CAUTION: Moving Parts Entanglement Hazard

Failure to observe these instructions could lead to minor or moderate injury. Reinforces safety around moving parts.

NOTICE: Equipment Damage

Warns against improper use of the bumper, like towing, to prevent equipment damage.

NOTICE: Driver Assist System Interference

Product may interfere with vehicle's driver assist systems; consult owner's manual.

Tools and Specifications

Tools Required

Lists the necessary tools for installation, including standard wrenches and sockets.

Torque Specifications

Provides recommended torque values for various fastener sizes during assembly.

Installation Steps

Step 1-6: Bumper Removal Preparation

Instructions for removing the license plate, frame bracket bolts, trailer harness, and bumper.

Step 7-11: Bumper Bracket and Frame Preparation

Details on removing small bolts, plastic covers, and freeing the bumper from frame brackets for reinstallation.

Step 12-15: Component Transfer and Sensor Installation

Guidance on transferring bumper trim, lamps, trailer receptacle, and sensors to the new bumper.

Step 16-20: Bumper Mounting and Securing

Instructions for positioning the bumper, securing it with specific hardware, and tightening all connections.

Step 21-24: Final Assembly and Finishing

Steps for installing light bezels, license plate, and ensuring all components are secured.

The provided document is an installation instruction manual for the WARN Ascent Rear Bumper, Part Number 98054, designed for the 2016+ Toyota Tacoma.

Function Description:

The WARN Ascent Rear Bumper is a replacement bumper designed for the 2016 and newer Toyota Tacoma. It is intended to enhance the vehicle's rear aesthetics and potentially offer improved durability or functionality compared to the factory bumper. The installation process involves removing the existing rear bumper and its associated components (license plate, trailer harness receptacle, license plate lamps, wiring harness, sensors, radar if equipped, and other electronic components) and then installing the new WARN bumper, reusing many of the original electronic parts. The bumper is designed to accommodate the vehicle's existing license plate, trailer receptacle, and lighting, as well as various sensors and radar systems.

Important Technical Specifications:

The manual provides a detailed parts list for the bumper assembly, including:

Bumper Weldment (A1): Part No. 98010, Quantity: 1. This is the main structural component of the bumper.
Light Bezel (A2): Part No. 96285, Quantity: 2. These bezels are for the light ports on the bumper.
Fasteners: A variety of hex head capscrews, lock washers, hex nuts, flat washers, cable ties, nylock nuts, stainless capscrews, panel nuts, and plastic locking plugs are listed with specific part numbers and quantities. For example:
- 1/2-13X1-1/2 HEXHEAD CAPSCREW (B1): Part No. 6818, Quantity: 2
- 5/8-11X1-1/2 HEX CAPSCREW (B2): Part No. 6819, Quantity: 2
- 5/8 LOCK WASHER (B3): Part No. 6820, Quantity: 2
- 5/8-11 HEX NUT (B4): Part No. 6821, Quantity: 2
- 1/2 FLAT WASHER (B5): Part No. 9213, Quantity: 4
- 5/8 FLAT WASHER (B6): Part No. 9471, Quantity: 4
- CABLE TIE (B7): Part No. 13231, Quantity: 2
- 1/2-13 NYLOCK NUT (B8): Part No. 29060, Quantity: 2
- STAINLESS CAPSCREW (B9): Part No. 91541, Quantity: 18
- PANEL NUT (B10): Part No. 96329, Quantity: 18
- PLASTIC LOCKING PLUG (B11): Part No. 98258, Quantity: 4

The manual also includes a comprehensive "TORQUE SPECIFICATIONS" table for various fastener sizes, both in lb-ft and N.m:

1/4": 8 lb-ft (11 N.m)
5/16": 17 lb-ft (23 N.m)
3/8": 30 lb-ft (40 N.m)
7/16": 48 lb-ft (66 N.m)
1/2": 74 lb-ft (100 N.m)
9/16": 106 lb-ft (144 N.m)
5/8": 148 lb-ft (200 N.m)
3/4": 269 lb-ft (364 N.m)
M4: 2 lb-ft (3 N.m)
M5: 4.5 lb-ft (6 N.m)
M6: 7.5 lb-ft (10 N.m)
M8: 18 lb-ft (25 N.m)
M10: 37 lb-ft (50 N.m)
M12: 111 lb-ft (150 N.m)

Usage Features:

The WARN Ascent Rear Bumper is designed to integrate with the existing vehicle systems, including:

License Plate: The original license plate is reinstalled on the new bumper.
Trailer Harness Receptacle: The factory trailer plug receptacle is transferred and reinstalled into the new bumper.
License Plate Lamps: The original license plate lamp holders are transferred and reinstalled.
Driver Assist Systems: The bumper is designed to accommodate factory wiring harnesses, sensors (such as parking assist sensors), and radar systems (adaptive cruise control). A critical "NOTICE" warns that the product may interfere with these systems and advises consulting the vehicle owner's manual, as these systems may need to be disabled.
Lighting: The bumper includes light ports for which light bezels are installed. A note advises cutting out the back of the bezel if installing lights.
Tow Bar Compatibility: A "NOTICE" explicitly states that WARN bumpers are not designed to be used for flat towing and advises against attaching tow bars directly to the bumper to prevent damage. Users should consult their tow bar system manufacturer for proper vehicle tow bar brackets.

Maintenance Features:

The manual outlines a clear maintenance and care regimen to ensure the longevity and safe operation of the WARN product:

Hardware Inspection: Before each use, all parts on the winch (if applicable, though this bumper is not a winch mount), winch mount, and related hardware should be inspected. Any rusted or deformed hardware must be replaced.
Nut and Bolt Inspection: All nuts and bolts on the winch (if applicable), winch mount, and related hardware should be inspected before each use. Loose nuts should be tightened, and stripped, fractured, or bent bolts or nuts must be replaced.
Cable Inspection: All cables (if applicable) should be checked prior to use. Worn or frayed cables must be replaced.
Moving/Rotating Parts Inspection: All moving or rotating parts (if applicable) should be checked. Any debris that might inhibit free movement must be removed.

General Safety Precautions:

The manual emphasizes safety throughout, using "WARNING," "CAUTION," and "NOTICE" signal words. Key safety points include:

Read Instructions: Thoroughly read all safety precautions and operating instructions before installation and operation.
Personal Judgment: It's impossible to warn about all potential hazards; users must exercise good judgment.
Drilling Caution: Use extreme caution when drilling to avoid puncturing fuel lines, brake lines, electrical wires, or other objects. Inspect the area to be drilled on both sides and relocate any objects that may be damaged.
Eye Protection: Always wear safety glasses when installing to prevent eye injury from flying metal chips.
Cutting/Trimming Caution: Use extreme caution when cutting and trimming during fitting.
Jewelry Removal: Always remove jewelry.
Battery Safety: Never lean over the battery while making connections.
Electrical Cable Routing: Never route electrical cables across sharp edges, through or near moving parts, or near hot parts.
Electrical Insulation: Always insulate and protect all exposed wiring and electrical terminals and install terminal boots as directed.
Lifting Components: Use appropriate and adequate care when lifting components.
Secure Components: Ensure components remain secure during installation and operation.
Tighten Hardware: Tighten all nuts and bolts securely per instructions.
Regular Inspections: Perform regular inspections and maintenance on the plow mechanism (if applicable), fasteners, cable, and related hardware.
Replace Damaged Parts: Replace all worn or damaged parts before operating.
Do Not Operate with Damaged/Missing Parts: Never operate this WARN product with damaged or missing parts.
Age Restriction: Never operate this product if under 16 years of age.
Impairment: Never operate this product when under the influence of drugs, alcohol, or medications.
Heavy Parts: Always use assistance when moving or lifting heavy parts.

The installation process is detailed with step-by-step instructions and corresponding figures, guiding the user through the removal of the factory bumper and the installation of the WARN Ascent Rear Bumper, including the transfer of various electronic components.