Warn 102145 User manual

©2018 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 1 102494A0
JEEP JL WRANGLER
FRONT CRAWLER BUMPER
Part Number: 102145, 102146, 102510, 102520
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 WinchingTechniques, 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 ensure 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.
BEFORE YOU BEGIN
THIS IS A 2-SIDED INSTRUCTION.
This side is for the the Jeep JL Wrangler.
Be sure to choose your precise application before you begin.

©2018 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 2 102494A0
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
Torque Specications......................................................................page 2
Tools Required...................................................................................page 3
Parts List...............................................................................................page 3
Installation ......................................................................................page 4-7
Maintenance/Care............................................................................page 7
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)
NOTICE
EQUIPMENT DAMAGE
• Never tow vehicle by attaching a tow bar to the eyelets on the bumper.
• Never attach tow bars directly to the bumper. Damage to bumper may occur. WARN bumpers are not designed to be used for at towing. Consult with the manufacturer of your tow bar system for the proper vehicle tow
bar brackets..
Read installation and operating instructions thoroughly.
NOTES
• The Warn Crawler Bumper will accept a large range of mid frame winches with up to 12,000 lb. capacities. The Bumper has been
designed to accommodate the standard 4-1/2 x 10” feet down mounting pattern as well as the 4-1/2 x 6” short drum pattern. The
Warn PowerPlant, 8274 and 9.5 CTI are NOT compatible with this bumper.
• Full width Crawler Bumpers are compatible with factory fog lamps using provided brackets. Stubby Crawler Bumpers do not reuse
factory fog lamps. Both Crawler Bumpers provide mounting locations for aftermarket lights on the top of the bumper.
• Both Crawler Bumper styles are not compatible with the factory skid plate and will not be reinstalled after installation of the
Crawler Bumper.
NOTICE
This product may interfere with driver assist systems such as adaptive cruise control and parking as-
sist 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.

©2018 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 3 102494A0
PARTS LIST
ID PN Description Qty.
A1 Varies Crawler Bumper 1
A2 87398 Winch Mount Plate 1
A3 102148 RH Foglight Bracket 1
A4 102147 LH Foglight Bracket 1
A5 102487 LH Anti-Nod (JL) 1
A6 102488 RH Anti-Nod (JL) 1
ID PN Description Qty.
B1 102491 Carriage Bolt - 1/2" - 13 x 1.25 8
B2 101259 Pushnut Bolt Retainer - 1/2" 8
B3 9213 Washer - 1/2" Plain Narrow 8
B4 29060 Locking Hex Nut - 1/2" - 13 8
B5 100772 Locking Plastic Plug - 3/8" 4
B6 83125 Flange Hex Nut - M6 x 1.0 4
B7 87166 Flange Nut Elastic Insert - M10 x 1.5 12
B8 93078 Flange Head Bolt - M10 x 1.5 x 25 8
B9 64108 Flange Head Capscrew - M6 x 1.0 x 25 6
B15 81707 Carriage Bolt - M10 x 1.5 x 40 4
B16 101447 Doubler Bracket JL Sport 2
B17 82351 Socket Head Capscrew - M4 x 0.7 x 16 4
B18 93675 Locking Hex Nut - M4 x 0.7 Nylon Insert 4
TOOLS REQUIRED
- Ratchet, extensions, universal
- Sockets: Standard and Metric
- End Wrenches: Standard and Metric
- Open End Wrenches

©2018 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 4 102494A0
INSTALLATION INSTRUCTIONS
1. Remove factory bumper.
2. If reusing fog lights, be sure to remove from stock bumper.
3. Use a small at head screwdriver to pry wire harness clips
upward.
4. Disconnect fog light harness Christmas tree clips from the
factory bumper.
NOTE: You will need to secure wiring up in new bumper with
zip ties.
5. Install the eight 1/2” carriage bolts (B1) into the bumper
mounting slot (four each side).
IMPORTANT: Be sure that bolts are completely seated
in bumper (with square edges lined up with slot) before
securing push nut.
Aline
edges
Figure 1
Figure 2
Figure 3
Figure 4

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Figure 6
Figure 5
6. Using a socket, secure bolt to bumper with push nut (B2).
TIP: Use an end of a tool to hold the back side of each bolt in
place while you secure push nut.
NOTE: The head of bolt will be in the inside of bumper hull
and the push nut will be on the outside.
7. Attach fog light to brackets (A3 and A4). NOTE: The fog
light may need to be trimmed to match the supplied fog
light bracket.
a. For LED fog lights: Secure light with two M6 ange head
bolts (B9) and M6 locking ange nuts (B6).
b. For HALOGEN fog lights: Secure with two M4
screws (B15) and M4 locking nut (B16).
NOTE: Halogen Fog light housing may need to be
trimmed to install further forward into bumper light
shroud.
NOTE: Your bracket may look dierent than image shows.
8. Attach fog light assemblies to bumper with two M10 ange
bolts (B8) and nuts (B7 ).
NOTE: Bracket mounting location may dier depending on
type of light.
Figure 7

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BUMPER INSTALLATION
9. With assistance, lift bumper in place (threading bolts
through frame mounting brackets).
10. Secure bumper to factory frame horns, using eight washers
(B3) and lock nuts (B4) (four each side).
ANTI-NOD INSTALLATION
(FOR STEEL BUMPER MODELS)
11. Remove the two bolts (each side) that attach the skid plate
mounting brackets to the frame. NOTE: Retain hardware
and brackets for anti-nod bracket installation.
(FOR PLASTIC BUMPER MODELS)
12. Insert one carriage bolt (B15) into the upper hole of frame
doubler plate (B16).
13. Place doubler plate onto frame, inserting carriage bolt into
upper frame hole.
14. Insert second carriage bolt through doubler plate and lower
frame hole. Repeat for both sides of vehicle.
Figure 8
Figure 9
CAUTION
• Always use assistance when moving or lifting heavy parts.
Figure 10
Skid Plate Mounting
Bracket
Frame doubler plate
and carriage bolt
Frame
Holes

©2018 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 7 102494A0
Figure 11
B8
A5/A6
Lower
Hardware
Figure 12
Figure 13
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.
(FOR ALL BUMPER MODELS)
15. Loosely secure top portion of anti-nod bracket (A5 and A6)
between bumper and frame using bolts (B8).
16. Secure lower portion of anti-nod bracket:
Steel Bumper: over the factory skid plate mounting
bracket and between the bumper and frame. Using
factory hardware NOTE: Be sure to install hardware in
the same orientation as removed.
Plastic Bumper: using two ange nuts (B7).
17. Tighten top bolts now.
18. Install fairlead to winch mounting bracket (A2).
19. Place winch mounting bracket on top of bumper (aligning
mounting holes). NOTE: We recommend getting assistance
to hold mounting bracket/fairlead in place to avoid tipping
hazard.
20. Install winch and wire to mounting bracket and bumper per
your winch installation instructions.
21. Tighten ALL hardware to specications on page 2.
22. Your installation is now complete.