Warn 103638 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 Sales/Customer Service: 1-503-722-3008
International Fax: [phone]
INSTALLATION INSTRUCTIONS
ASCENT FRONT BUMPER KIT
Part Number: 103638
Application: 2019 Dodge Ram 1500
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.
WARNING
IMPACT AND MOVING PARTS ENTANGLEMENT HAZARD
Failure to observe these instructions could lead to severe injury or death
• Always Know Your Winch. Take time to fully read the Instructions and/or Operations Guide, and/or Basic Guide to Winching Techniques, in order to understand
your winch and its operations.
• Never work under vehicle before properly securing vehicle.
• Always use appropriate and adequate care in lifting components into place.
• Never work under vehicle before properly securing vehicle.
• Always use appropriate and adequate care in lifting components into place.
• Never use a jack to support the vehicle.
• Always use jack stands in pairs to support the vehicle.
• Always use jacks or jack stands only on a hard, stable, and level surface.
• Never exceed the rated capacity of a jack or jack stands.
• Always verify that the parking brake is set, the transmission is in park (automatic) or reverse (manual) and the rear wheels are blocked before working on vehicle.
• Never work under vehicle before properly securing vehicle.
• 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 and operation.
• Always perform regular inspections and maintenance on the winch, winch mount and related hardware.
• Always replace all worn or damaged parts before operating.
• Never operate this WARN product with damaged or missing parts.
• 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 use extreme caution when cutting and trimming during tting.
• Always wear safety glasses when installing this kit. A drilling operation will cause ying metal chips. Flying chips can cause eye injury.
• Always remove jewelry and wear eye protection.
• Never lean over battery while making connections.
• Never route electrical cables across any sharp edge, through or near moving parts, near parts that become hot.
Read installation and operating instructions thoroughly.
GENERAL SAFETY PRECAUTIONS

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Tools Required.................................................................. page 2
Parts List.............................................................................. page 3
Torque Specications..................................................... page 3
Installation ......................................................................page 4-9
Maintenance/Care........................................................... page 9
EQUIPMENT DAMAGE
• Never tow vehicle by attaching a tow bar to the eyelets on the bumper.
• Do not 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.
MOVING PARTS ENTANGLEMENT HAZARD
Failure to observe these instructions could lead to minor or moderate injury
• Part edges may be sharp!
• Always use proper posture / lifting technique or get lifting assistance while handling and installing product.
Read installation and operating instructions thoroughly.
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.
NOTICE
CAUTION
NOTES
BEFORE YOU BEGIN
TABLE OF CONTENTS
- Standard Wrench and Socket Set
- Metric Wrench and Socket Set
TOOLS REQUIRED

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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)
PARTS LIST
TORQUE SPECIFICATIONS
Item PN Description Qty.
A1 102453 BUMPER 1
A2 103691 SPACER 2
A3 103636 CROSSMEMBER WELDMENT 1
A4 95648 RH MOUNTING BRACKET 1
A5 95643 LH MOUNTING BRACKET 1
A6 100903 LH LIGHT BRACKET 1
A7 100904 RH LIGHT BRACKET 1
A8 94889 LH LIGHT PORT 1
A9 94888 RH LIGHT PORT 1
Item PN Description Qty.
B1 100661 9/16 LOCKING PLUG 6
B2 102248 1-3/32 PLUG 6
B3 93106 M12 FLAT WASHER 52
B4 70117 M12-1.75-LOCK INSERT 26
B5 25552 M12-1.75 x 40 HEX HEAD CAPSCREW 26
B6 103640 M14-2.0X60 FLANGE BOLT 2
B7 91541 10-24X1 STAINLESS CAPSCREW (not shown) 20
B8 96329 PANEL NUT (not shown) 20
A2
A1
A6
A9
B2
A3
B1
B3, B4, B5
A6

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INSTALLATION INSTRUCTIONS
1. Remove fender liner:
. Using an 8mm socket, remove the three screws in
fender well. Repeat for other side.
b. Remove the two remaining lower screws to release
fender liner. Repeat for other side.
c. Slide fender line down and out.
2. If equipped, unplug the wiring harness located in the
front left corner of the bumper.
Figure 1
Fender well bolt
Figure 2
Figure 3

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INSTALLATION INSTRUCTIONS
3. Using an 18mm socket, remove the three nuts retaining
the stock bumper. Repeat for other side.
CAUTION
Always use assistance when moving or lifting heavy parts.
4. Carefully remove bumper and set on a clean and stable
surface.
5. If equipped, remove the active air dam.
a. Unplug the motor and remove the four retaining
nuts with a 12mm socket (see Figure 5 and 6) .
NOTE: The air dam will not be reinstalled with the
new bumper.
Remove nuts
Unplug
Remove nuts
Figure 4
Figure 5
Figure 6

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INSTALLATION INSTRUCTIONS
Figure 7
Figure 8
Figure 9
6. Remove sensors from sensor carriages.
a. Spread the top and bottom tabs of the sensor
carriage outward.
b. From the outside of the bumper, push sensor
towards the inside of the bumper. NOTICE Be
sure to mark the location and orientation of each
sensor plug.
TIP: Numbering each sensor with tape and marking the top
with a paint pen works well.
7. Remove the carriages from stock bumper.
a. Squeeze in the two tabs on the side of the carriages
and push each carriage out the front of the bumper.
8. Release the plastic clips holding the wire harness in place
and remove completely.
9. From the front of the bumper, carefully insert each
sensor carriage into the correct mounting hole and
snap into place. NOTE: Be sure sensors match the
orientation of the stock bumper.
Tab
Tab
Tab
Tab
Figure 10

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INSTALLATION INSTRUCTIONS
Figure 13
Figure 12
Figure 14
10. Route the factory wiring harness to new bumper. NOTE:
Be sure that the wiring harness will not interfere with
winch operation. It may be necessary to extend portions
of the wiring harness.
11. Install sensors into the correct sensor carriage in the new
bumper. NOTE: Be sure sensors match the orientation of
the stock bumper.
12. Secure the front mounting brackets (A4 and A5) to the
new bumper by installing six bolts (B5) with six washers
(B3) into the mounting hole and secure with six washers
(B3) and nuts (B4) and (each bracket). NOTE: Ensure that
the bolts are at the top of the slots in the bumper in order
to move the brackets as high as possible relative to the
bumper.
13. Line up crossmember (A3) with brackets.
14. Using a 19mm socket and wrench, loosely mount the
crossmember to the mounting brackets and bumper
by installing 8 bolts (B5) with 8 washers (B3) into the
mounting hole and securing with 8 washers (B3) and
nuts (B4).
CAUTION
Always use assistance when moving or lifting heavy parts.
NOTE: For the next step we recommend getting assistance
from one or two more people.
15. With assistance, line up the bumper/crossmember
assembly to the vehicle bumper mounting holes. NOTE:
The tabs on the back of the crossmember should slide
over the vehicle frame pad.
16. Using a 19mm socket and wrench, secure the bumper
& crossmember assembly to the vehicle by installing six
bolts (B5) with six washers (B3) into the mounting holes
and secure with six washers (B3) and nuts (B4) and (each
side).
17. Insert one spacer (A2) between the crossmember’s
corner tab and the vehicle frame (each side).
18. Insert one bolt (B6) up through crossmember’s tab, the
spacer and the vehicle’s mounting hole. Repeat for other
side.
19. Tighten all bumper hardware now, refer to torque
specications on page 3.
B5, B4, B3
Tab
B5, B3, B4
Spacer
B6
A5
B5, B4, B3
Figure 11

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INSTALLATION INSTRUCTIONS
20. Install winch and fairlead per winch installation
instructions. Tighten all hardware now.
21. Connect sensor wiring harness. NOTE: If not installing
sensors, plug unused holes with provided hole plugs (B2).
Refer to exploded view on page 3.
22. While holding light bracket (A6 and A7) in place (from
under and behind bumper), line up light port (A8 and
A9) through front bumper light port to bracket. Secure
pieces together with ten stainless steel socket head
screws (B7).
NOTE: Light ports are equipped with removable panels for
lights. Lights shown installed sold separately.
23. If not installing sensors and ascent bumper accessories,
plug unused holes with provided hole plugs (B5 and B4).
Refer to exploded view on page 3.
24. The remaining hardware (B1 and B2) are to used to install
license plate to new bumper.
25. Tighten ALL hardware now, refer to torque specications
on page 3.
26. If not installing a Baja Bar, insert plugs (B1) into the holes
in the top of the bumper.
CARELESS INSTALLATION AND OPERATION CAN RESULT IN SERIOUS INJURY OR EQUIPMENT DAMAGE. READ AND UNDER-
STAND ALL SAFETY PRECAUTIONS AND OPERATING INSTRUCTIONS BEFORE INSTALLING AND OPERATING THIS PRODUCT.
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.
A6 and A7
B7
Figure 15
Figure 16

©2019 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 9 105968A0
INSTALLATION INSTRUCTIONS
CARELESS INSTALLATION AND OPERATION CAN RESULT IN SERIOUS INJURY OR EQUIPMENT DAMAGE. READ AND UNDER-
STAND ALL SAFETY PRECAUTIONS AND OPERATING INSTRUCTIONS BEFORE INSTALLING AND OPERATING THIS PRODUCT.
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.