Warn 104823 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 Locater Service: 1-800-910-1122
International Fax: [phone]
INSTALLATION INSTRUCTIONS
Ascent Rear Bumper
Part Number: 104823
Application: 2019 Dodge Ram 1500
GENERAL SAFETY PRECAUTIONS
WARNING
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.
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.

©2019 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 2 106693A0
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
Parts List.........................................................................................................................................page 3
Torque Specications................................................................................................................page 3
Installation ................................................................................................................................page 4-6
Maintenance/Care......................................................................................................................page 6
TOOLS REQUIRED
- Standard Wrench and Socket Set
- Metric Wrench and Socket Set
BEFORE YOU BEGIN
NOTICE
This product is not compatible with factory 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.

©2019 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 3 106693A0
PARTS LIST
Item PN Description Qty.
A1 105715 BUMPER 1
A2 105755 FRAME BRACKET 2
A3 105760 LIGHT PLATE 2
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) M4 (2) 3
1/4" 8 (11) M5 (4.5) 6
5/16" 17 (23) M6 (7.5) 10
3/8" 30 (40) M8 (18) 25
7/16” 48 (66) M10 (37) 50
1/2" 74 (100)
9/16” 106 (144)
5/8" 148 (200)
3/4” 269 (364)
Item PN Description Qty.
B1 83125 M6 X 1.0 FLANGED NUT 8
B2 79153 M6-1.0 X 16MM FLANGE BOLT 4
B3 84881 M6 X 1 X 20MM STAINLESS SCREW 4
B4 87166 M10 X 1.50 FLANGE NUT 12
B5 79583 M10 X 1.5 X 30 FLANGE BOLT 12
B6 102248 PLASTIC PLUG 6
B7 13231 ZIP TIE 12
A3
B6
A2
A1
B4
B5
B2
B3
B1
B4

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INSTALLATION INSTRUCTIONS
1. Using a 10mm socket, remove license plate.
2. Remove the two plastic push pins and two bolts from
license plate location.
3. From underneath the vehicle, at the rear driver’s side
corner, unplug the bumper harness and unsnap from
vehicle frame.
4. While supporting the bumper, remove the two bumper
mounting nuts using a 16mm socket (each side).
Figure 1
Figure 2
Figure 3

©2019 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 5 106693A0
INSTALLATION INSTRUCTIONS
5. Carefully remove bumper and set on a clean and stable
surface.
6. If your bumper is equipped with sensors, carefully
remove from the carriages. 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. Release the plastic clips holding the wire harness in place
and remove harness from bumper completely.
8. Unsnap trailer plug from stock bumper.
9. Remove license plate lights from stock bumper by
removing the bolt on the rear of each housing with a
10mm wrench.
10. Reinstall trailer plug and license plate lights into new
bumper.
11. Install the sensor carriages into the new bumper by
either of the two methods below:
a. Using a razor blade, cut the sensor carriages out of
the stock bumper and carefully glue into the new
bumper with a waterproof adhesive or epoxy.
b. Order new carriages for the FRONT bumper of your
specic year and model from a Dodge dealer and
press them into the holes on the new bumper.
12. Install sensors into carriages. NOTE: Be sure sensors
match the same orientation of the stock bumper.
13. If installing lights, install now. If not, install light plate
(A3) using two M6 screws (B3) (each side). Refer to
exploded view on page 3.
14. Install frame brackets (A2) to bumper using four M10
bolts (B5) and nuts (B4). Do not fully tighten to allow for
adjustment. Refer to exploded view on page 3.
Figure 4
Figure 5
Sensors
Trailer Plug
License Plate Lights
Sensors
Trailer Plug
License Plate Lights
A3 and B3
Figure 6
Figure 7
A2 A2
B5
&
B4
B5
&
B4
B5
&
B4
B5
&
B4

©2019 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 6 106693A0
INSTALLATION INSTRUCTIONS
CAUTION
Always use assistance when moving or lifting heavy parts.
15. With assistance, lift bumper up to stock frame mounting
points and secure into place with four M10 bolts (B5) and
nuts (B4) through slots in the mounting brackets. Do not
fully tighten to allow for adjustment.
16. Align bumper to truck body, allowing bumper clearance
from tailgate (freely opens and shuts).
17. Once you have position conrmed, tighten ALL hardware
to torque specications on page 3.
18. Plug in all necessary wiring harness connections (license
plate light, sensors, etc.) and secure up and out of the way
with included zip ties.
19. If vehicle is not equipped with sensors, use provided
plugs (B6) in sensor holes.
Installation is now complete.
B4
B5
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 8
Figure 9