Warn 98054 User manual

©2016 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 1 98271A1
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: 98054
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 98271A1
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 4-8
Maintenance/Care......................................................................................................................page 8
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) M12 (111) 150
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 98271A1
PARTS LIST
Item Part No. Description Qty.
A1 98010 BUMPER WELDMENT 1
A2 96285 LIGHT BEZEL 2
Item Part No. Description Qty.
B1 6818 1/2-13X1-1/2 HEXHEAD CAPSCREW 2
B2 6819 5/8-11X11/2 HEX CAPSCREW 2
B3 6820 5/8 LOCK WASHER 2
B4 6821 5/8-11 HEX NUT 2
B5 9213 1/2 FLAT WASHER 4
B6 9471 5/8 FLAT WASHER 4
B7 13231 CABLE TIE 2
B8 29060 1/2 - 13 NYLOCK NUT 2
B9 91541 STAINLESS CAPSCREW 18
B10 96329 PANEL NUT 18
B11 98258 PLASTIC LOCKING PLUG 4

©2016 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 4 98271A1
INSTALLATION INSTRUCTIONS
1. Remove license plate.
2. Remove all ve bumper frame bracket bolts on each side of
vehicle. Keep the bolts as you will be reinstalling in a later
step.
3. Unclip the trailer harness receptacle, by squeezing the two
tabs together and push outward.
4. Remove the bumper and place on at surface.
5. Remove the trailer plug receptacle (shown already removed).
6. Remove the license plate lamps by
twisting the bulb holder to unplug
then squeeze the two tabs and remove
the lamp housing from the bumper.
Figure 1
Figure 2
Figure 3
Trailer Plug
License Plate
Lamps
Tabs
Figure 4

©2016 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 5 98271A1
7. Remove the two small metric bolts from side of the bumper.
Repeat for other side.
8. Un-snap the plastic cover on top of the bumper in order to
gain access to the upper bolts holding the frame brackets to
the bumper.
9. Lift up the top plastic piece, located above the bumper
frame brackets, to expose bolts.
10. Remove necessary hardware to free bumper from frame
bracket.
11. Reinstall bumper bracket/hitch back onto vehicle the same
way it was removed by reinstalling the bolts previously
removed in Step 2.
Tighten hardware now. Refer to torque specications on
page 2.
INSTALLATION INSTRUCTIONS
Figure 6
Figure 7
Un-snap
Figure 8
Figure 9

©2016 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 6 98271A1
12. Remove factory plastic bumper trim piece (both sides).
13. Remove the wiring harness, sensors, radar (if equipped) and
any other electronic component from the rest of the bumper
shell.
NOTE: If removing vehicle rear sensors, take care when
removing as you will be reinstalling in new bumper in the
same orientation.
14. Reinstall the license plate lamp holders and trailer receptacle,
that you previously removed from the stock bumper, into
your new bumper.
15. Install factory wiring harness, sensors (if equipped) and any
other electronic component to the new WARN bumper.
Tip: If reinstalling sensors: You will need to install in two pieces.
a. Unclip sensor from sensor retainer.
b. Insert sensor retainer through the front of the bumper.
Remember to insert in the same orientation as stock
bumper.
c. Clip sensor onto sensor retainer from the back of the
bumper., making sure it is tightly clipped (four clips).
* Sensor and receptacle shown in image may not exactly match your specic
sensor.
Figure 12
Figure 11
Figure 10
Sensor Retainer
Sensor
Trailer Receptacle
License lamp
Figure 13
Figure 14

©2016 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 7 98271A1
16. With assistance, slide bumper into position.
17. Bumper brackets should sit on the inside of factory bumper
brackets.
18. Secure forward mounting hole on new bumper with ½ inch
hardware.
19. Secure rear mounting hole on new bumper with 5/8 inch
hardware.
20. Tighten all hardware at this time.
21. Place the nut clips over the light port holes as shown.
NOTE: If you are installing lights to your bumper, rst cut
the back of the bezel out before installing bezel to bumper.
22 Insert light bezel (A2) through bumper light port and align
with nut clips. Secure bezel with ten stainless steel socket
head screws (B9). Review exploded view on page 3.
23. Repeat for other side.
Figure 15
B2, B6, B3, B4
B1, B5, B8
CAUTION
• Always use assistance when moving or lifting heavy parts.
Figure 17
Figure 16

©2016 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 8 98271A1
24. Install license plate to bumper using the two stainless screws
and panel nuts.
25. Installation is now complete.
Figure 18
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.