Warn 104256 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: 104256
Application: 2019 Dodge Ram 2500/3500
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
Maintenance/Care............................................................page x
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
- Reciprocating saw or other cutting tool
- Masking tape
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 105811 LH FRAME BRACKET 1
A2 104261 RH FRAME BRACKET 1
A3 100903 LH LIGHT BRACKET 1
A4 100904 RH LIGHT BRACKET 1
A5 94889 LH LIGHT PORT 1
A6 94888 RH LIGHT PORT 1
A7 104257 BUMPER 1
Item PN Description Qty.
B1 83125 M6 FLANGED NUT (not shown) 2
B2 64108 M6 FLANGE BOLT 2
B3 101259 1/2” PUSHNUT BOLT RETAINER 8
B4 100661 9/16 LOCKING PLUG 2
B5 102248 1-3/32 PLUG 8
B6 91541 STAINLESS SCREWS 20
B7 105967 ZIP TIE ADHESIVE ANCHORS (not shown) 6
B8 68380 ZIP TIE (not shown) 8
A3
A4
A6
A7
B3
B5
B4
A1
B2

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INSTALLATION INSTRUCTIONS
Disconnect the vehicle battery cables, negative terminal rst. All
work with electrical wires and cables must be completed with
the battery completely disconnected from the vehicle wiring.
1. Using a 10mm socket, remove screw in fender well
securing the fender liner to the bumper. Repeat for
other side.
2. If vehicle is equipped with front sensors or fog lights,
unplug the bumper wiring harness from the main
vehicle harness. NOTE: Be sure to note the location
and orientation of the sensors prior to removal, this is
important for the reinstall.
3. From underneath the vehicle, at the front corner of
the frame rails, remove the nuts and bolts securing
the bumper and tow hooks. Retain hardware for re-
installation.
a. The light colored tow hook bolts require a 24mm
socket, the nut on the inboard side of the frame is
captive.
b. The dark colored bumper mount bolts require
an 18mm socket and wrench as the nut is free to
rotate.
c. 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. Using a 24mm socket and wrench, remove the two
bolts and nuts and the blocker bar (each side) from the
vehicle.
Figure 1
Figure 2
Figure 3
Fender well bolt
Bumper bolts
Tow hook bolts
Remove
Blocker bar
Figure 4

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INSTALLATION INSTRUCTIONS
6. From the inside of the bumper, remove the eight nuts
and carriage bolts securing the stock frame brackets.
Retain hardware for re-installation.
7. Remove the sensors from their 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.
8. Remove the carriages from stock bumper.
a. Squeeze in the two tabs on the side of the carriages.
b. Push each carriage out the front of the bumper.
9. Release the plastic clips holding the wire harness in place
and remove completely.
Figure 5
Figure 6
Tab
Tab
Tab
Tab
Figure 7
Figure 8

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INSTALLATION INSTRUCTIONS
10. Install the eight stock carriage bolts into the new
bumper and secure loosely using the included push nuts
(B3). TIP: It is helpful to secure push nut to bumper and bolt
with a socket.
NOTE: Do not tighten push nut down to allow for
adjustment.
11. From the front of the bumper, carefully each sensor
carriage into the correct mounting hole and snap into
place. NOTE: Be sure sensors match the orientation of
the stock bumper.
12. Route the factory wiring harness and sensors into the
new bumper.
a. Thread harness through the upper holes of the
internal structure.
NOTE: Be sure sensors match the orientation of the
stock bumper.
b. Install sensors into coordinating sensor carriage.
c. Secure wire harness up and away from potential
moving parts (i.e. winch rope) using supplied zip ties (B8)
and zip tie adhesive anchors (B7) at the locations marked
In Figure 10.
13. Install the fairlead to bumper per your winch installation
instructions.
Upper holes
Figure 9
Figure 10
xxxx
Figure 11
Figure 12

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INSTALLATION INSTRUCTIONS
14. Mount winch to bumper per winch installation
instructions.
15. Using the stock tow hook and bumper bolts, install the
left (A1) and right (A2) frame brackets to vehicle frame.
Do not tighten to allow for adjustments.
TIP: The small arrows on the face of the brackets will
point in towards each other.
16. Route winch power cables up along frame rail and
toward battery.
NOTE: Make sure to route wires/cables away from sharp
edges, heat and moving parts.
NOTE: Zip tie in regular intervals to keep cables/wiring in
place.
CAUTION
Always use assistance when moving or lifting heavy parts.
17. With assistance, lift the new bumper in position and slide
the carriage bolts into the mounting holes on each frame
bracket.
18. Loosely secure the bumper with the eight factory nuts
removed in step 1. TIP: The upper nuts may be easier to
access through the cutouts in the bumper.
19. With the bumper loosely held in place, center it left and
right.
20. With the bumper centered, level it and set the height (we
recommend a gap of approximately ½ inch between the
bumper and fenders). TIP: A oor jack placed underneath
each bumper corner can be helpful in leveling the
bumper.
Bumper
bolts
Tow hook
bolts
Arrows
Frame brackets
Figure 13
Figure 14
Figure 15
Figure 16

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INSTALLATION INSTRUCTIONS
21. Once bumper is centered and level, tighten hardware
to recommended torque on page 3.
22. Trim fender liners.
a. Mark along the fender liner with masking tape.
b. Carefully cut liner with a reciprocating saw or other
cutting tool. NOTICE Avoid cutting into the washer uid
reservoir or any wiring harnesses on the back side of the
fender liner.
WARNING
Always use extreme caution when cutting and trimming during
tting.
23. While holding light bracket (A4) in place (from under
and behind bumper), line up light port (A6) through
front bumper light port to bracket. Secure pieces
together with ten stainless steel socket head screws
(B6).
NOTE: Light ports are equipped with removable panels
for lights. Lights shown installed sold separately.
24. Repeat for other side.
25. 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.
26. The remaining hardware (B1 and B2) are to used to
install license plate to new bumper.
27. Tighten ALL hardware now, refer to torque
specications on page 3.
28. Reconnect battery connections.
A4 and A6
B6
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.
Figure 17
Figure 18