Warn 61854 User manual

WARN INDUSTRIES 62060 Rev. B1PAGE1
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, fire or personal injury.
Always wear safety glasses when installing this kit. A drilling operation will cause flying metal chips. Flying chips can cause eye
injury.
Always use extreme caution when cutting and trimming during fitting.
Always remove jewelry and wear eye protection.
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.
WARNING
Failure to observe these instructions could lead to severe injury or death.Failure to observe these instructions could lead to severe injury or death.
Failure to observe these instructions could lead to severe injury or death.Failure to observe these instructions could lead to severe injury or death.
Failure to observe these instructions could lead to severe injury or death.
Yoursafety,andthesafetyof others,isveryimportant.Tohelpyoumakeinformeddecisionsaboutsafety,we haveprovidedinstallation
andoperatinginstructionsandotherinformationonlabelsandinthisguide.Thisinformationalertsyoutopotentialhazards thatcouldhurt
youorothers.Itisnotpossibletowarn youaboutall potentialhazardsassociatedwiththisproduct,youmustuseyourowngoodjudg-
ment.
CARELESS INSTALLATION AND OPERATION CAN RESULT IN SERIOUS INJURYOR
EQUIPMENT DAMAGE. READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND
OPERATING INSTRUCTIONS BEFORE INSTALLING AND OPERATING THIS PRODUCT.
Thisguideidentifiespotentialhazardsandhasimportantsafetymessagesthathelpyouandothersavoidpersonalinjuryordeath.WARN-
INGand CAUTIONaresignalwordsthatidentifythelevel ofhazard.Thesesignal wordsmean:
WARNINGsignalsahazardthatcouldcauseseriousinjuryordeath,ifyoudonotfollowrecommendations.
CAUTIONsignalsahazard that maycauseminortomoderateinjury, ifyoudonotfollowrecommendations.
ThisguideusesNOTICEto callattentionto importantmechanicalinformation, andNote: toemphasizegeneralinformationworthyof
specialattention.
INSTALLATION INSTRUCTIONS
FOR JEEP REAR BUMPERS
TJ P/N 61854, YJ P/N 61857,
CJ P/N 61860
NOTES: On some TJ and YJ models, it may be necessary to loosen the gas tank skid plate to allow
for enough hand room to access the inner bolt hole locations
VI. INSTALLATION
1. Remove the rear bumper from vehicle.
·On TJ models, discard bumper and mounting hardware.
·On YJ models, discard bumper and mounting hardware.
·On CJ models, discard bumper and mounting hardware.
2. Install new, Warn, rear bumper on vehicle.
·On TJ models, use the supplied 3/8" bolts, lockwashers, and washers in all 8 mounting
locations. Torque 3/8" bolts to 35-38 ft lbs. Insert the two spacers, one on each side, between
the bottom bumper tab and the bottom of the frame. Install the bottom bumper bolts, using the
2 supplied 7/16" bolts, lockwashers, and washers, torque 7/16" bolts to 42-45 ft lbs.

WARN INDUSTRIES 62060 Rev. B1PAGE2
INSTALLATION CONT.
NOTE: Some TJ model vehicles may not have all 8 mounting locations on the rear frame
area. If all 8 locations are not in the frame, measure the supplied bumper mounting points and
match these measurements on the frame. Drill the frame holes to 7/16". See Figure 1.
·On YJ models, use the supplied 3/8" bolts, lockwashers, and washers in all 8 mounting
locations. Torque 3/8" bolts to 35-38 ft lbs. Insert the two spacers, one on each side, between
the bottom bumper tab and the bottom of the frame. Install the bottom bumper bolts, using the
2 supplied 7/16" bolts, lockwashers, and washers, torque 7/16" bolts to 42-45 ft lbs.
·On CJ models, use the supplied 3/8" bolts, lockwashers, and washers in all 8 mounting
locations. Insert the four spacers between the frame surface and the bumper mounting
surface. It is necessary to space the bumper away from the frame for proper clearance.
Torque 3/8" bolts to 35-38 ft lbs. Insert the two spacers, one on each side, between the
bottom bumper tab and the bottom of the frame. Install the bottom bumper bolts, using the 2
supplied 7/16" bolts, lockwashers, and washers, torque 7/16" bolts to 42-45 ft lbs.
WARN INDUSTRIES, INC. g12900 SE CAPPS ROAD gCLACKAMAS, OR 97015-8903
[phone] gg
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gCUSTOMER SERVICE LINE 1-888-722-6730 gg
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gFAX [phone]
Figure 1
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