Warn 103209 User manual

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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
SEMI HIDDEN KIT
Part Number: 103209
Application: 2014+ Toyota Tundra
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 toWinchingTechniques, 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.

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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 4-8
Maintenance/Care................................................................................................................... page 8
TOOLS REQUIRED
- Standard wrenches
- Standard sockets
- Reciprocal saw or other cutting tool
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
1 103206 LH BUMPER BRACKET 1
2 103195 RH BUMPER BRACKET 1
3 102846 SEMI HIDDEN WELDMNT 1
ITEM PART NO. DESCRIPTION QTY
4 83125 M6 X 1.0 NUT 2
5 64108 M6-1.0 x 25 BOLT 2
6 102248 BLACK PLASTIC PLUG (not shown) 2
2
1
3
4
5

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INSTALLATION INSTRUCTIONS
1. Using a 10mm socket, remove grille by removing the four
front center screws, as well as the two outer push pins.
2. Remove one plastic clip from fender liner (both sides).
3. Using a 17mm socket, remove the two bolts securing the
tow hook (each side). Remove tow hook and set aside. Save
tow hook and bolts for reuse.
Figure 1
Figure 2
Figure 3
Plastic clips
10mm bolts
Plastic clip

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4. Remove three screws holding bumper to skid pan.
Optional: Remove skid pan to increase access for upcoming
installation.
5. From underneath the bumper, use a 14mm socket to remove
the four nuts (each side) holding the bumper structure to
the frame rails. Save nuts for reuse.
6. If equipped, disconnect harness from rear of fog lamps and
disconnect park sensor harness (both sides).
WARNING
Always use assistance when moving or lifting heavy parts.
6. Remove and set aside bumper.
Figure 5
Figure 6
Figure 4

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7. From inside of the stock bumper, remove the plastic fender
liners by removing the 10 fasteners (ve on each side) using
a 10mm socket.
8. Using a 12mm socket, remove the remaining hardware
securing the bumper structure and front bumper
reinforcement bar to the bumper. Retain hardware for later
use.
9. Using a 14mm socket, remove the 6 nuts securing the
bumper structure to the reinforcement bar. Retain
hardware for later reinstall.
10. Reinstall bumper structure using the original hardware. Do
not completely tighten to leave room for adjustment.
11. Install new the left (1) and right (2) bumper brackets to the
stock bumper, using the six reinforcement bar nuts.
12. From the outside of the bumper, use a reciprocating saw or
similar tool to carefully cut out the center plastic (following
styling lines). Tip: Mask cut lines to prevent unnecessary
damage.
NOTE: Relocating the control pack can be done to avoid
next step.
For winches with top mounted control pack only:
13. From the inside of the bumper, carefully cut a 10 x 2 inch
section out of the center of the bumper support rib. NOTE:
Be sure to cut only on the support rib. Do not cut through
the outside of the bumper.
NOTE: For winches with a remote plug on the side of the
contactor, extend the cutout and additional four inches,
making the cut out 14 x 2 inches.
Remove Fasteners
Remove
Bumper Structure (left side)
LH & RH bumper brackets
Bumper structure
Bumper structure
Carefully cut
Top Mounted
Control Pack
For remote
plug
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Remove nuts

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Figure 13
14. Reinstall the plastic fender liners using original hardware.
15. Mount the fairlead to the semi hidden weldment (3),
according to your winch mounting instructions.
16. Mount the winch to the semi hidden weldment according to
your winch mounting instructions
WARNING
Always use assistance when moving or lifting heavy parts.
17. With assistance, place bumper in position on vehicle. Do not
install nuts yet.
18. Before installing the semi hidden weldment/winch assembly,
route the winch power cables through the cutout in the
bumper and in front of the radiator.
Figure 15
Figure 16
Winch
Fairlead
Figure 14

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Figure 17
WARNING
Always use assistance when moving or lifting heavy parts.
19. With assistance, line up the semi hidden weldment/winch
assembly.
20. Slide it underneath the bumper and then up into position
(lining up mounting studs).
21. The winch control pack is the part that must pass
underneath and into the space you trimmed out. NOTE:
More trimming may be necessary to obtain accurate t.
NOTE: Be sure to keep winch power cables clear of weldment
assembly.
22. Once accurate t is achieved, install the four factory
mounting nuts (4 per side). Do not tighten to allow for
adjustment.
23. Adjust and center the bumper and semi hidden assembly
horizontally. NOTE: Horizontal adjustment is at the frame
pad studs.
23. Align the stock bumper vertically. NOTE: Vertical alignment
of the stock bumper is adjusted at the bumper bracket
vertical slots. TIP: We recommend using a oor jack to help
with this.
24. Now that all the hardware is installed:
a) Check to make sure that there isn’t to much space
between the frame brackets and the bumper.
b) Conrm bumper is centered and aligned vertically and
horizontally.
c) Once satised with alignment, torque all hardware
to suggested values on page 2. NOTE: Always make
adjustments with assistance.
25. Installation is now complete. Use the two bolts (5) and
nuts (4) to install license plate to the front of the weldment.
NOTE: Plastic plugs (6) are included for the two lower front
winch access holes.
Factory nuts
Figure 18
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.
Figure 19