Warn 97684 User manual

©2016 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 1 98178B0
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 Front Bumper
Part Number: 97684
Application: 2016+ Toyota Tacoma
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.

©2016 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 2 98178B0
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 4-10
Maintenance/Care................................................................................................................... page 10
TOOLS REQUIRED
- Standard wrenches
- Standard sockets
- Hacksaw Blade with Handle (ne tooth)
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)
NOTICE
EQUIPMENT DAMAGE
• Never tow vehicle by attaching a tow bar to the eyelets on the bumper.
• Never 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.

©2016 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 3 98178B0
PARTS LIST
ID No. Item No. Description Qty.
B1 6818 1/2-13X1-1/2 Hex Capscrew 10
B2 9213 1/2 Flat Washer 20
B3 2596 1/2 Lock Washer 18
B4 1323 1/2-13 Hex Nut 12
B5 2146 7/16 Lock Washer 4
B6 220026 7/16 Flat Washer 12
B7 2583 7/16-14 Hex Nut 4
B8 15834 7/16-14X1-3/4 Hex Capscrew 2
B9 3693 Flat Spacer 4
B10 91541 10-24X1-Stainless Screw 20
B11 100661 9/16 LOCKING PLUG 6
ID No. Item No. Description Qty.
A1 97751 Bumper 1
A2 97943 Frame Bracket LH 1
A3 97942 Frame Bracket RH 1
A4 95458 Light Bracket RH 1
A5 95438 Light Bracket LH 1
A6 97986 Support Bracket 2
A7 94889 Light Bezel LH 1
A8 94888 Light Bezel RH 1
B11

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INSTALLATION INSTRUCTIONS
1. Remove license plate.
2. Carefully, remove the front facia plastic by rst removing
the screws and plastic push clips from the inner fender skirt.
That will allow you to reach between fender skirt and plastic
facia to release clips.
3. Unclip and remove the plastic cover plate attached to the
aluminum cross bar.
4. Remove the four fasteners from underneath the bumper.
Figure 1
Figure 2
Figure 3
Unclip
Figure 4
Remove

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5. To remove the cross tube, you will rst need to remove the
three nuts from each side of the aluminum cross bar.
NOTE: Because there is a bracket attached to the ends of the
cross tube that need to clear the plastic before it will come
out, you will need to carefully slide the aluminum bar out one
side at a time.
6. Remove the plastic nut from the ends of the brackets. Retain
as you will be reinstalling later.
7. Remove the three nuts securing the aluminum frame
extension. Remove extension. Retain the nuts as you will be
reusing them.
Repeat for other side.
8. Remove the grille insert.
a. Unsnap the six clips to remove the light covers from
grille.
b. Reach through opening behind the grill to unsnap the
19 plastic clips and two wire retaining clips that are
holding grille to body plastic.
c. Once all clips have been unsnapped, remove grille
completely.
INSTALLATION INSTRUCTIONS
Figure 5
Figure 6
Figure 7
Remove
Figure 8
Light cover plastic
Grille

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9. Your vehicle should be stripped down to look like this.
10. Run a tape line down each side of the body plastic prole
that use to hold the factory front facia plastic piece you
removed in step 2.
11. Use the outside of the front facia outline and the inside of
the tape line as your cut line. Be careful as to not cut inner
fender.
NOTICE
Avoid cutting the screw holes on each side and
bottom of body plastic, as they will be reused.
WARNING
Always use extreme caution when cutting and trimming during
tting. Make sure that all fuel lines, brake lines, electrical wires, and other objects
are not punctured or damaged when cutting on the vehicle. Thoroughly inspect the
area to be cut (on both sides of material) prior to cutting, and relocate any objects
that may be damaged. Failure to inspect the area to be cut may result in vehicle
damage, electrical shock, re or personal injury.
12. After front facia is cut out completely, cut along plastic fog
lamp plastic bracket. Follow along the edge of bracket. The
fog lamp and plastic bracket will come out as one assembly.
* Figure 12 shows completed removal of plastic cut.
Figure 9
Figure 10
Cut line
Screw hole intact
Cut along edge of
light bracket
Figure 11
Figure 12

©2016 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 7 98178B0
13. Reinsert plastic nut (both sides) back into the inner fender
well.
14. Reinstall the screw removed in step 4 (both sides). This is
how it will look after the plastic is cut.
15. From underneath vehicle, remove the bolt just outside of
tow hook (both sides). It will be the bolt that holds the stock
frame insert piece to the vehicle. Keep bolt as you will be
reusing them to attach bumper supports. Do not remove the
tow hook bolts.
16. Before installing frame bracket you will need to cut out a
small notch in the plastic air shroud.
a. Hold frame bracket in place and mark area on shroud
to notch (enough to clear the frame extension bracket).
Carefully cut notch and t up bracket.
b. Slide new frame bracket over the three bolts left where
you removed the aluminum frame extensions and
lightly hold into place using the factory nuts in step 7.
Leave nuts loose at this time to allow for adjustment.
Figure 13
Figure 14
Inside view of screw hole
intact with plastic nut
and screw reinstalled
Remove
Figure 15a
Install
Figure 15b
Notch

©2016 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 8 98178B0
17. To set the spacing between the brackets:
a. Measure the outside to outside of inner bumper ribs.
b. Measure the distance from inside to inside of brackets
on truck and space and center brackets accordingly.
18. Finish securing each bracket with one 7/16 bolt (B8), two
spacers (B9), one washer (B6), lock washer (B5) and nut (B7).
Refer to exploded view on page 3.
19. Fasten the support bracket (A6) using the hardware
previously removed in step 13.
Connect support bracket to the frame bracket using the
7/16 bolt (B8), washers (B6), lock washers (B5) and nut (B7)
hardware found in your hardware kit. Refer to exploded
view on page 3.
Thread the hardware in but do not tighten.
(B8), (B9), (B6), (B5)
and (B7)
Figure 16a
Figure 17
Figure 18
Factory hardware
(B8), (B6), (B5)
and (B7)
Figure 16b

©2016 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 9 98178B0
20. This is a good time to zip tie your fog lamp harnesses to any
convenient place so it will not be in the way.
Cover the end with electrical tape so dirt and debri does not
enter plug.
21. With assistance hang the bumper (A1) on the frame brackets.
22. Secure with four ½ bolts (B1), eight washers (B2), four lock
washers (B3) and nuts (B4). Refer to exploded view on page 3.
Do not tighten at this time.
Repeat for other side.
23. Insert the last remaining 7/16” hardware (just below the four
bolts just installed).
24. Make sure there is not too much space between the frame
brackets and the bumper.
The bumper should be centered from side to side on front
fenders.
25. Tighten all frame bracket hardware. Double check the frame
brackets to vehicle.
26. Check the height of the bumper from side to side and make
any necessary adjustments.
27. Tighten all bumper mounting hardware at this time.
CAUTION
• Always use assistance when moving or lifting heavy parts.
(B1), (B2), (B3),
and (B4)
(B1), (B2), (B3),
and (B4)
Figure 19
Figure 20
Figure 21
Figure 22

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28. While holding light bracket (A4) in place (from under and
behind bumper), line up light bezel (A8) through front
bumper light port to bracket. Secure pieces together
with ten stainless steel socket head screws (B10). Review
exploded view on page 3.
29. Repeat for other side.
NOTE: Light bezels are equipped with removable panels for
lights. Lights shown installed are sold separately.
30. Reinstall license plate.
31. If not installing optional Ascent bar accessories, plug unused
holes with provided hole plugs (B11). Refer to exploded
view on page 3.
32. Your installation is now complete.
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.
A10
Figure 23