AEV BISON WINCH KIT User manual

INSTALLATION GUIDE
BISON WINCH KIT
FOR COME UP WINCH
AEV30330AA
Last Updated: 08/05/19

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PLEASE READ 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.
INCLUDED PARTS QTY REQUIRED TOOLS
Bison Winch Fairlead 1Common Hand Tools
Controller Mount Bracket 1
Hardware Pack 1

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I. DISASSEMBLY
1. Disconnect and isolate the negative battery cable.
2. Remove Front Bumper Skid.
A. Remove the 4 M4 torx screws attaching the license plate bracket (fig. 1).
B. Remove the 2 M10 bolts in middle of Front Bumper Skid (fig. 2).
C. Remove the 2 torx bolts from bottom of Front Bumper Skid (fig. 2).
Figure 1 Figure 2
3. Remove Skid 1B by removing the 6 bolts (fig.3 ).
Figure 3

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4. Remove the 6 M10 torx bolts attaching the center section of bumper (fig. 4).
5. Remove the 12 push clips attaching the air diverter (fig. 5).
Figure 4 Figure 5
6. Remove LH and RH wheel liner closeouts (fig.6).
Figure 6
7. Remove Cage nuts in bumper for winch fairlead (fig. 7).
Figure 7

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8. Remove 1 M10 bolt on radiator support and SAVE (fig. 8).
9. Remove 1 M6 bolt on radiator support and SAVE (fig. 8).
10. Un-clip radiator overflow hose (fig. 8).
Figure 8
II. ASSEMBLY
1. Remove in-line fuse attachment from the harness (fig. 9).
Figure 9
2. Route the harness through the Controller Bracket, and re-install in-line fuse.

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3. Assemble Come Up controller onto the Controller Bracket with existing screws (fig. 10).
Figure 10
4. Lay the assembly into the engine bay to start routing the wire looms.
5. Route the mesh covered loom through the opening near the horn toward the underside of the vehicle (fig. 11).
FRONT OF VEHCILE
FRONT OF VEHCILE
Figure 11

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6. Position the controller bracket in place and loosely install the radiator support bolts removed earlier (fig. 12).
Figure 12
7. Install supplied bolt through the tab at the bottom of the bracket into the existing hole shown (fig. 13).
FRONT OF VEHCILE
FRONT OF VEHCILE
Figure 13
8. Run the wiring loom over the radiator overflow hose and across the front of the vehicle. Detach the
radiator supports to run the loom underneath as shown (fig. 14) then reinstall fasteners.
Figure 13

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9. Rout the other end of the harness through the bottom of the engine bay (fig. 15)
Figure 15
10. Attach ground from the main harness to the ground stud. Attach the negative cable supplied with the
winch to the ground stud, routing the other end toward the battery. Secure with supplied M8 x 1.25 nut
(fig. 16).
TO NEGATIVE
BATT. TERMINAL
GND
Figure 16
11. Rout the positive battery lead to the battery. DO NOT hook up at this time.

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12. Install winch body (fig. 17).
A. Start two M10 x 30mm bolts in bottom locations.
B. Start two M10 x 100mm bolts in top locations to help align the winch body.
C. Tighten bottom bolts.
D. Remove top winch bolts for now. These will be re-installed after Skid 1A and 1B have been installed.
A A
BB
Figure 17
13. Connect wiring to winch.
A. Feed wire looms into winch cavity as shown (fig. 18). Leave service loop at pencil braces to allow for
body movement. Zip-tie wire harness at pencil braces.
Figure 18
B. Attach main wires matching colors.
C. Attach ground wire.
D. Connect Plug.

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Figure 19
14. Secure wire loom with zip ties (fig 20).
Figure 20
15. Run the winch cable through the Bison fairlead and drop into place (fig. 21).
Figure 21

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16. Trimming the air diverter (fig. 22).
A. Using scribe line and template (AEV30342) cut air diverter for handle and spool
B. Reinstall air diverter with 12 clips
Figure 22
17. Reinstall Center section of bumper
18. Reinstall Wheel Liner Closeouts
19. Reinstall Skid 1B (fig. 3).
20. Reinstall Front Bumper Skid (fig. 2).
21. If you live in a State requiring a front license plate, you will need to drill holes for the fasteners.
NOTE: Mid-year 2020 vehicles will have holes for the ¼ turn fasteners and push-in fasteners.
Option A: Mount license plate over fairlead. (fig. 23A).
Option B: Mount license plate curved under fairlead (fig. 23B).
A. Center license plate and mark holes for drilling.
B. Drill 7/16” holes, de-burr, and treat with rust preventative.
C. Insert supplied push-in fasteners and attach license plate.
Figure 23A Figure 23B
22. Install winch hook per manufacturers recommendations

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23. Trim the pre-fuse case and lid to make space for the positive winch connection (fig. 24).
RECOMMENDED: Add RTV sealant to the trimmed areas of the pre-fuse case.
TRIM
Figure 24
24. Route positive and negative lines as shown (fig. 25).
NOTE: Route positive line under inner fender and around pre-fuse case. Route negative line underneath
battery bracket and fender trim. Use zip-ties to secure in-line fuse to one of the cables o the pre-fuse case.
Figure 25: Positive (red) Negative (green)

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25. Attached positive line in the pre-fuse case (fig. 26).
Figure 26
26. Attach negative line to the battery (fig. 27).
Figure 27
27. Spool winch according to manufacturers recommendations.