AEV WINCH MOUNT 2021+ COLORADO ZR2 User manual

INSTALLATION GUIDE
WINCH MOUNT
2021+ COLORADO ZR2
AEV30439AA
Last Updated: 01/05/21
PLEASE READ ENTIRELY BEFORE YOU START
To guarantee a quality installation, we recommend reading these instructions thoroughly
before beginning any work. These instructions assume a certain amount of mechanical
ability and are not written nor intended for someone not familiar with auto repair.
TABLE OF CONTENTS
I. DISASSEMBLY
II. PREPARATION
III. INSTALLATION
REQUIRED TOOLS
Common Hand Tools
Air Saw or Cut O Wheel

WINCH MOUNT 2021+ COLORADO ZR2
11
8
7
3
4
5
9 10
6
14
13
1
12 2
ITEM NO.
PartNo
DESCRIPTION
QTY.
1
AZRB0106AA
RECIEVER WINCH MOUNT
1
2
AZRB0101AA
LH FRAME HORN MOUNT
1
3
AZRB0100AA
RH FRAME HORN MOUNT
1
4
AZRB0104AA
CORNER CRASH BRACE
2
5
AZRB0103AA
NUT PLATE
2
6
AZRB1018AA
TRIM PANEL
1
7 11588740
M10 X 1.5 X 40 FLANGE BOLT
8
8
AEV93002AB
M10 X 1.5 FLANGE NUT
4
9
AEV98008AC
1/2 WASHER
6
10
AEV91037AA
M12 X 1.75 X 30 HCS
6
11
AEV93001AB
M12 X 1.75 FLANGE NUT
6
12 11548583
M6 X 1.0 U-NUT
6
13 11570779
M6 X 1.0 X 20 PAN HEAD BOLT
4
14
AEV91164AA
M6 X 1.0 X 40 SBHCS
2

1
AMERICAN EXPEDITION VEHICLES
I. DISASSEMBLY
1. Remove Front Fascia
2. Remove Factory Intrusion Beam
II. PREPARATION
1. Cut o the lower portion of the Factory Grill Support as shown (fig. 1).
AIR TEMP SENSOR
Figure 1
1. Trim Fascia
A. Cutout the provided template (PN: AEV30414AA)
B. Align the template to the license plate dimples on the front fascia (fig. 2).
Figure 2
C. Cut out the center for winch mount as directed on the template (fig. 3).
Figure 3

2
AMERICAN EXPEDITION VEHICLES
2. Install six M6 U-nuts onto the winch mount center section as shown (fig. 4).
Figure 4
III. INSTALLATION
1. Install frame mount brackets using two M10 bolts in the factory locations (fig. 5).
M10
Figure 5: Driver-side Shown

3
AMERICAN EXPEDITION VEHICLES
2. Insert flag nut into frame rail and start two M10 bolts (fig. 6).
Figure 6
NOTE: Do Not install tow hooks at this point.
3. Install center section using three M12 bolts per side (fig. 7).
Figure 7: Driver-side shown

4
AMERICAN EXPEDITION VEHICLES
4. Reinstall tow hooks using factory hardware (fig. 8).
NOTE: tow hooks sits under bracket.
Figure 8
5. Tighten all fasteners. Torque M10 bolts to 43 ft-lbs and M12 bolts to 74 ft-lbs.
Torque Tow Hook nuts to 118 ft-lbs. NOTE: while tightening pull upward on tow hooks.
6. Install side crush beams using two supplied M10 bolts and nuts (fig. 9). Torque nuts to 43 ft-lbs.
Figure 9: Passenger-side shown

5
AMERICAN EXPEDITION VEHICLES
7. Trim the upper, inside corners of the factory foam and around tow hooks (fig. 10)
TRIM FOAM
Figure 10
8. Reinstall Factory Grill support.
9. AEV recommends Warn Cradle mount 89990. This comes with Anderson connectors to wire winch.
Refer to Warn Installation Instructions.
10. Route Power and ground from Anderson connector below plastic fascia support, up below headlight
and to battery (fig. 11). NOTE: do not connect battery yet!
Figure 11
11. Reinstall OEM Fascia
12. Reinstall Front Skid Plate. NOTE: If using AEV’s Front License Plate Mount (PN: 18060015), follow mount-
ing instructions for that product first.
13. Install Winch Closeout panel to vehicle using four M6 x 30 BHCS, torque to 7 lb-ft

6
AMERICAN EXPEDITION VEHICLES
14. Bolt Anderson connector to winch mount with two M6 x 40mm BHCS, Torque to 7 lb-ft. (Fig. 12).
Figure 12
15. Connect winch power leads to battery
16. Trim the battery box and lid to make space for the positive winch connection (fig. 13).
Figure 13

7
AMERICAN EXPEDITION VEHICLES
17. Attached positive line to battery.
18. Route the negative lead alongside the battery and connect to the negative terminal (fig. 14).
Figure 14
19. Install Winch in Cradle. AEV recommends AEV Winch Cradle (PN: 18060018AA) for storing winch and
transporting winch while not in use.