Warn 100838 User manual

©2018 Warn Industries, Inc.WARN® and the WARN logo are trademarks ofWarn Industries Inc. 1 100837A0
WARN INDUSTRIES, INC. 12900 S.E. Capps Road,
Clackamas, OR USA 97015-8903, 1-503-722-1200, FAX: [phone]
Customer Service: 1-800-543-9276
Dealer Locator Service: 1-800-910-1122
International Fax: [phone]
INSTALLATION INSTRUCTIONS
ASCENT FRONT BUMPER
Part Number: 100838
Application: 2018 Ford F-150
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 toWinching 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 thisWARN 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.

©2018 Warn Industries, Inc.WARN® and the WARN logo are trademarks ofWarn Industries Inc. 2 100837A0
NOTICE
EQUIPMENT DAMAGE
• Always refer to the Installation and Specication Guide, supplied in the winch kit, for all wiring schematics and specic details on how to wire this WARN product to your vehicle.
Read installation and operating instructions thoroughly.
CAUTION
MOVING PARTS ENTANGLEMENT HAZARD
Failure to observe these instructions could lead to minor or moderate injury
• Always take time to fully read and understand the installation and Operations Guide included with this product.
• Never operate this product if you are under 16 years of age.
• Never operate this product when under the inuence of drugs, alcohol or medications.
Read installation and operating instructions thoroughly.
TABLE OF CONTENTS
Tools Required.............................................................................................................................page 2
Torque Specications................................................................................................................page 2
Parts List.........................................................................................................................................page 3
Installation ................................................................................................................................page 4-9
Maintenance/Care......................................................................................................................page 9
TOOLS REQUIRED
- Standard wrenches
- Standard sockets
BEFORE YOU BEGIN
NOTICE
This product may interfere with driver assist systems such as adaptive cruise control and parking assist systems that have sensors or cameras installed in
the bumpers or front grill area. If your vehicle is equipped with any of these systems or features, consult your vehicle owner’s manual before installing
this product. These systems may need to be disabled as a result of installing this product.
TORQUE SPECIFICATIONS
Please use the recommended torque specications when assembling this product unless otherwise specied in the instructions.
FASTENER SIZE FASTENER TORQUE FASTENER SIZE FASTENER TORQUE
lb-ft (N.m) lb-ft (N.m)
1/4" 8 (11) M4 (2) 3
5/16" 17 (23) M5 (4.5) 6
3/8" 30 (40) M6 (7.5) 10
7/16” 48 (66) M8 (18) 25
1/2" 74 (100) M10 (37) 50
9/16” 106 (144)
5/8" 148 (200)
3/4” 269 (364)

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PARTS LIST
ITEM PART NO. DESCRIPTION QTY
A1 100839 BUMPER 1
A2 100903 ASCENT LGHT BRKT LH 1
A3 100904 ASCENT LGHT BRKT RH 1
A4 100847 WLDMNT BMPR BRKT LH 1
A5 100848 WLDMNT BMPR BRKT RH 1
A6 100855 WLDMNT FRM BRKT LH 1
A7 100856 WLDMNT FRM BRKT RH 1
A8 94888 LIGHT PORT RH 1
A9 94889 LIGHT PORT LH 1
A10 100929 CHNL FRM BRKT B LH 1
A11 100928 CHNL FRM BRKT B RH 1
A12 38452 NUT STICK ASSY 2
A13 79913 TUBE SPACER 2
A14 95514 AIR SCROOP 1
ITEM PART NO. DESCRIPTION QTY
B1 22535 ½-13 X 1 ¾ CPSCR HEX HEAD BOLT 14
B2 68896 5/8-11 X 6 CPSCR HEX HEAD BOLT 2
B3 68959 5/8 FLAT WASHER 4
B4 6820 5/8 LOCK WASHER 2
B5 6821 5/8-11 HEX NUT 2
B6 11294 1/2-13 X 2 HEX HEAD CAPSCREW 6
B7 1145 ½ FLAT WASHER 40
B8 2596 ½ LOCK WASHER 20
B9 1323 1/2 -13 NUT 18
B10 91541 10-24 X X1.25 SS SOC HD CPSCR 20
B11 1824 7/16-14 X 1-1/4 HEX HEAD CPSCR 4
B12 7676 7/16 FLAT WASHER 8
B13 2146 7/16 LOCK WASHER 4
B14 2583 7/16-14 HEX NUT 4
B15 90327 5/16-18 X 1 ¼ SOC HD CPSCR 5
B16 90328 5/16-18 NUT LOCKING 5
B17 100661 9/16 LOCKING PLUG 6
B17

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INSTALLATION INSTRUCTIONS
1. From underneath the vehicle, unplug fog lamps.
2. From underneath the vehicle, remove the fog lamp plug,
harness clip and air dam christmas tree clip to free the
bumper. The fog lamp harness will hang freely and will need
to be secured with zip ties underneath the vehicle. Figure 2.
3. Repeat for other side.
4. Remove the two outer christmas tree clips holding plastic
sheeting (located between top edge of bumper and the bottom
of the grille). NOTE: The third center christmas tree clip will
be removed as you are removing the bumper from the front
of the vehicle.
5. Remove license plate and frame.
6. Remove the two front plastic bumper inserts and clips, from
bumper. See Figures 4 and 5.
Wire harness clip
Unplug wire
harness
Christmas tree
clip
Figure 1
Figure 2
Figure 3
Figure 4

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7. From inside the bumper, remove the four nuts (two on each
side) as shown in Figure 6. After removing nuts, you can
freely remove the tie bolt plate from behind the bumper.
8. Get help to hold bumper in place.
9. From underneath the vehicle, remove the last remaining nut
holding bumper in place (each side). See Figure 7.
INSTALLATION INSTRUCTIONS
Figure 5
Figure 6
CAUTION
• Always use assistance when moving or lifting heavy parts.
Figure 7
Remove

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10. Remove the rubber boot and the two bolts from tow hook.
You will not be reusing.
11. Remove tow hook. You will not be reusing. See Figures 8
and 9. Repeat for other side.
NOTE: If model is equipped with eco-boost, cutting the soft
rubber from the around the innercooler will aid in
bumper installment.
12. Insert spacer (A13) into the vehicle frame (behind front
ange). Figure 10.
13. Repeat for other side.
14. Hold left hand bottom frame bracket (A6) in place, using
washer (B3) on bolt (B2). Bracket will hang in place until fully
secure. Do not tighten at this time. Figure 11.
15. Repeat for other side.
Figure 8
Figure 9
Rubber boot
Tow hook
Remove bolts
Figure 10
Figure 11
A13
A6
B3, B2

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INSTALLATION INSTRUCTIONS
16. Align left hand inner bracket (A10) with bolt from previous
step.
17. Secure in place (hand tighten only) with lock washer (B4) and
nut (B5). Figure 12.
18. Do not tighten at this time.
19. Using three bolts and washers (B1& B7), attach the left hand
bottom frame bracket(A6). Insert the rst two bolts (B1) with
washers (B7) through bracket and vehicle frame. Fasten with
washer (B7), lock washer (B8) and nut (B9).
20. Insert the last (most rear) bolt (B1) with lock washer (B8) and
washer (B7). Fasten with nut assembly (A12).
21. Check position of bracket, making sure it is as close to the
back of the vehicle’s bumper mounting ange as possible.
Once in place, tighten bottom hardware at this time.
22. Clip excess nut assembly wire handle o, making even with
end of frame.
23. Tighten 5/8” bolt (B2) installed in step 15.
24. Remove clamp and tighten all hardware at this time.
25. Repeat steps 16-24 for other side.
NOTE: You may wish to remove the two side impact bars
at this time, because after bumper installment is
complete, the impact bars will be exposed. See Figure
18.
Figure 14
Figure 12
Figure 13
A10
A12
B7, B8 and B9
Side impact bars

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INSTALLATION INSTRUCTIONS
26. Install front frame brackets (A4 & A5) using hardware B6, B7,
B8 and B9. Refer to exploded view on page 3. See Figure 15.
27. Slide bumper (A1) in place and loosely attach to front frame
brackets using B1, B7, B8 and B9. Do not tighten at this time.
Figure 16.
28. With assistance, adjust bumper and tighten all hardware at
this time.
29. While holding light bracket (A2) in place (from under and
behind bumper), line up light bezel (A9) through front
bumper light port to bracket. Secure pieces together
with ten stainless steel socket head screws (B10). Review
exploded view on page 3.
30. Repeat for other side.
NOTE: Light bezels are equipped with removable panels for
lights. Lights shown installed - sold separately.
Figure 16
Figure 17
Figure 15
A4 & A5
A9
B1, B7, B8 & B9

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31. For Models with intercooler feature ONLY: For maximum
air ow, install air scoop (A14) from behind bumper, using
ve B15 and B16 hardware.
32. If not installing optional Ascent bar accessories, plug unused
holes with provided hole plugs (B17). Refer to exploded
view on page 3.
33. Installation is now complete.
Figure 18
B15 and B16
MAINTENANCE / CARE
1. Inspect all parts on the winch, winch mount, and related hardware prior to each use. Replace all hardware that appears rusted or
deformed.
2. Inspect all nuts and bolts on the winch, winch mount,, and related hardware prior to each use. Tighten all nuts that appear to be
loose. Stripped, fractured, or bent bolts or nuts need to be replaced.
3. Check all cables prior to use. Replace cables that look worn or frayed.
4. Check all moving or rotating parts. Remove debris that may inhibit the part from moving freely.
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.