Warn 96550 User manual

©2015 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 1 96551A2
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
ASCENT REAR BUMPER
Part Number: 96550
Application: 2015+ Chevrolet 1500, 2500 and 3500
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 toWinching Techniques, 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.

©2015 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 2 96551A2
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
Removal of the OEM bumper for the 1500..................................................................page 4-6
Removal of the OEM bumper for the 2500 and 3500.............................................page 7-9
Installation ...........................................................................................................................page 10-14
Maintenance/Care................................................................................................................... page 14
TOOLS REQUIRED
- Standard wrenches
- Standard sockets
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
A1 96552 BUMPER WELDMENT 1
A2 96285 LIGHT BEZEL 2
ITEM PART NO. DESCRIPTION QTY
B1 91541 SOCKET HEAD SCREW 10-24 18
B2 96329 U-CLIP NUTS 18
B3 90846 PLASTIC PLUG 4
B4 6818 HEX HEAD BOLT 4
B5 9213 FLAT WASHER 8
B6 29060 LOCK NUT 4
B7 8160 3/8-16 X 1.5 HEX HEAD BOLT 2
B8 11524 3/8 FLAT WASHERS 4
B9 6779 3/8 LOCK NUTS 2
B10 13231 BLACK ZIP TIES 12
B11 69427 FLAT WASHER 2
B12 98180 NUT ASSEMBLY 2
B12

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INSTALLATION INSTRUCTIONS
The following steps are for the removal of
the OEM bumper for the 1500:
1. Remove rear license plate.
2. From underneath the rear bumper, unplug the trailer
connector wire harnesses.
3. Unplug license plate light wire harness and back up sensors (if
equipped).
NOTICE
Be careful when removing sensors and sensor
retainer from bumper as to not damage .
Figure 1
Figure 2
Figure 3

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4. Remove spare tire rod lock.
NOTE: It might be easier if you remove the spare tire at
this time in order to lift the bed of the truck, however; if
you have the right size blocks it may not be necessary.
5. Remove the two bolts (one on each side of the license plate
opening) that attach the center of the bumper to the hitch.
NOTE: You may remove the trailer harness receptacle at
this time by depressing the two metal clips - or wait until
bumper is removed.
6. Remove the two frame nuts and the one frame bolt (each
side). Figure 6.
Figure 6
Figure 4
Remove bolt
Frame NutsFrame Bolt
Figure 5

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7. Remove the bolt located underneath the frame rail inside
the hitch mount. Retain bolt - as you will be reinstalling later using the
nut assembly supplied in this kit.
The bumper is now unbolted.
NOTE: To be able to remove the bumper with the frame
brackets, you will need to lift the back of the pickup box/
bed.
8. Un-bolt the box’s rear bolts (one on each side of truck). You
will need an extension to reach the bolt.
9. Next you will loosen the box’s front bolts (located about two
feet toward the front of the vehicle from the rear bolt just
removed).
There will be a large hole that you can insert a socket and
extension through to loosen the bolt (one on each side).
10. Repeat steps for other side.
11. With assistance, carefully remove bumper.
12. Using the nut assembly (B2), reinstall the bumper bracket
bolt which was previously removed in step 7.
Repeat for each side.
Go to page 10 for your WARN Bumper
installation instructions.
Remove
Figure 7
Figure 8
Figure 9
Figure 9

©2015 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 7 96551A2
INSTALLATION INSTRUCTIONS
The following steps are for the removal of
the OEM bumper for the 2500/3500:
1. Remove rear license plate.
2. From underneath the rear bumper, unplug the trailer
connector wire harnesses, license plate and sensor wiring
harness (if applicable).
NOTICE
Be careful when removing sensors and sensor
retainer from bumper as to not damage .
4. Remove spare tire rod lock.
NOTE: It might be easier if you remove the spare tire at
this time in order to lift the bed of the pickup, however; if
you have the right size blocks it may not be necessary.
Figure 1
Figure 2
Figure 3

©2015 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 8 96551A2
5. Remove the two bolts (one on each side of the license plate
opening) that attach the center of the bumper to the hitch.
NOTE: You may remove the trailer harness receptacle at
this time by depressing the two metal clips - or wait until
bumper is removed.
6. Using a socket, remove three bolts attaching OEM bumper to
frame.
7. Remove the bumper bracket bolt. Retain bolt - as you will be
reinstalling later using the nut assembly supplied in this kit.
NOTE: To be able to remove the bumper with the frame
brackets, you will need to lift the back of the pickup box/
bed.
9. Un-bolt the box’s rear bolts. You will need an extension to
reach the bolt.
10. Repeat steps for other side.
INSTALLATION INSTRUCTIONS
Figure 6
Figure 4
Remove bolt
Figure 5
Remove Frame Bolts
Bumper
Bracket Bolt
Box/Bed rear
bolt

©2015 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 9 96551A2
11. Approximately two feet in front of the bolts you just
removed, located on the outside of the frame, is the forward
box mounting bolt.
12. Remove bolt to allow the pickup bed/box to raise.
13. Repeat for other side.
14. Find the rib or rail, underneath the pickup box/bed and use
oor jack with blocks to slightly lift the box (approximately.
1/2 inch).
15. With assistance, carefully remove bumper.
16. Using the nut assembly (B2), reinstall the bumper bracket
bolt which was previously removed in step 7.
Go to page 10 for your WARN Bumper
installation instructions.
Remove
CAUTION
• Always use assistance when moving or lifting heavy parts.
NOTICE
• Only lift the bed approximately a 1/2 inch, only to gain enough clearance to remove the
stock bumper brackets from the frame rails. Lifting too much can damage the pickup box or
other components.
Figure 7
Figure 8

©2015 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 10 96551A2
Figure 2
The following steps are for the installation
of your new WARN bumper for the 1500,
2500/3500:
1. Remove the trailer harness receptacle (unless previously
removed), by squeezing the two tabs together and push
outward.
2. Unplug license plate lamp by twisting bulb housing and
removing screw.
3. If vehicle is equipped with vehicle rear sensors, remove now.
NOTE: The sensor unclips from the sensor retainer, then
the retainer unclips from the bumper. See Figures 9 and
10.
NOTICE
Be careful when removing sensors and sensor
retainer from bumper as to not damage .
4. Repeat steps for other side.
5. Carefully, remove OEM spare tire access housing. NOTE:
Using a pick, bend each prong back and out of way. Take
care, bending prongs as to not damage because you will
be reusing in new bumper.
Trailer harness
receptacle
Tabs
License Plate
Lamp and screw
Sensor Retainer
Sensor
Sensor and Sensor
Retainers
Figure 1
Figure 3

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6. Using two small screwdrivers, pry the inner ring loose from
the outer ring by unsnapping the four detents holding in
place.
7. Remove outer ring from stock bumper and insert in new
bumper.
8. Carefully bend prongs back in place on the inner ring and
reinstall in new bumper. See Figure 6 and 7.
Figure 4
Figure 5
Figure 6
Figure 7

©2015 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 12 96551A2
9. Insert the OEM spare tire access housing to rings in new
bumper.
10. Insert trailer harness receptacle into new bumper.
11. Insert one u-clip nut (B2) over lower tab on license plate
lamp weldment.
u-clip
Figure 8
Figure 9
Figure 10

©2015 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 13 96551A2
12. Insert license plate lamp plug as shown in gure 11.
13. Secure with one screw (B1).
14. Plug in license plate lamp harness.
15. Repeat steps for other side.
16. If applicable, install the stock sensor retainers into new
bumper.
17. From behind bumper, route the sensor harness through
frame bracket and insert in sensor retainer.
NOTE: If your vehicle did not come equipped with rear
sensors, use the supplied plugs to cover sensor locations.
Screw
License Plate
Lamp Plug
Figure 11
Sensor retainer
Figure 12
Figure 13

©2015 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 14 96551A2
18 a. Slide bumper into place, lining up holes in bumper
brackets to mounting holes in vehicle frame.
b. Install mounting hardware (loosely). See gure 14 and
refer to page 3.
c. Center bumper.
d. Tighten all hardware.
19. Install spare tire rod locking cover and nish securing any
loose wiring with zip ties provided.
20. Install the 8 panel nuts (each side) over light bezel holes in
light cut out (see exploded view on page 3).
21. Install light bezels and secure using the stainless hardware
provided in your kit.
22. Installation is now complete.
Figure 14
Figure 15
Figure 16
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.