Warrior Products 3520 User manual

Protecting Your Adventure Lifestyle
========================================================================================
QUALITY • INTEGRITY • INNOVATION • SERVICE
Warrior Products, Inc.
16850 SW Upper Boones Ferry Rd
Ste. A
Durham, OR 97224
Phone [phone]
Fax [phone]
[email protected]
FJ Cruiser Front Bumper
INSTALLATION INSTRUCTIONS
WAR 3520/3530
The Warrior Products 3520 & 3530 FJ Cruiser bumpers are designed to fit the XRC 8K thru 12K
series of winches and although the bumper has a fairly roomy interior for winch fitment, Warrior
Products makes no guarantees to the compatibility of other winch brands. When fitting the bumper it
is a good idea to have a helper available as the bumper can be a bit cumbersome and heavy for one
individual to handle alone, particularly when pre-fitted with a winch.
1. Begin the installation by removing the OEM grill, front bumper cover and all associated trim
pieces outlined below.
a. Temporarily remove the headlight surround/grill by accessing the push-pins and screws
along the top side and some clips along the bottom inside. Lift it out of the way and set it
aside.
b. Remove the stock plastic bumper cover by accessing the push-pins along the topside and
the lower bumper retaining screws and a couple screws located in the forward edge of
each wheel well.
c. The ends of the plastic cover can now be flexed out and then the entire cover moved
away and down off of the bumper reinforcement bracket.
d. Remove the inner bumper reinforcement bracket with extensions and retain the nuts for
installation of the Warrior bumper.
e. Remove the front bumper upper retainer.
f. Remove the molded plastic front bumper side supports; one on either side.
g. The inner fender well liners will have a ‘bowled’ section hanging down. Trim this
section off at the fender well ceiling.
h. The front fenders will now need to be reattached to the body. Snap the square nylon nut
into the square hole visible after removing the molded plastic front bumper side supports
and use the provided _” x _” bolt with _” flat washer to fasten the front fender mounting
tab back onto the body.
2. The vehicle should now be ready for installation of the bumper.

Protecting Your Adventure Lifestyle
========================================================================================
QUALITY • INTEGRITY • INNOVATION • SERVICE
Warrior Products, Inc.
16850 SW Upper Boones Ferry Rd
Ste. A
Durham, OR 97224
Phone [phone]
Fax [phone]
[email protected]
3. Using an assistant, lift the bumper up and onto the 8 frame-cap mounting studs. The oblong
holes are slightly oversized to allow proper visual alignment as the frame and body will not
always be exactly parallel to each other. Be aware of the notch in the winch plate for clearance
of the condenser line. If the line is in contact with the bumper or frame it will need to be
reshaped slightly. (see instructions below)
a. To minimize the strain on the lower fitting while reshaping the tubing, temporarily use a
small spacer such as a piece of wood or plastic that fits between the condenser line and
the radiator support just above the lower fitting. Gently flex the line until it is within a _”
of the horizontal core support located approx 6” inches above the fitting and centered
within the notch on the winch plate.
4. Thread the nuts onto the studs, but only hand-tighten at this time.
5. Place the winch plate frame brackets on top of the frame just inboard of the body lift spacers.
Insert the 3/8” bolts through the brackets and into the corresponding oblong holes in the winch
plate of the bumper. Place the split washers on the bolts and thread the nuts up from underneath
the bumper. Do not tighten at this time.

Protecting Your Adventure Lifestyle
========================================================================================
QUALITY • INTEGRITY • INNOVATION • SERVICE
Warrior Products, Inc.
16850 SW Upper Boones Ferry Rd
Ste. A
Durham, OR 97224
Phone [phone]
Fax [phone]
[email protected]
6. Reinstall headlight surround/grill.
7. Visually align the bumper by lining up the top edge of the bumper with the bottom edge of the
grill. Once you have the horizontal and vertical spacing to your liking, tighten the (8) mounting
nuts to 48 ft lbs.
8. Going back to the winch plate frame brackets; insert the 3/8” x 1-1/4” hex bolts with split
washers through the brackets and into the corresponding oblong holes in the top of the winch
plate to locate the brackets position on the frame. Thread on the nuts and washers, but do not
tighten at this time. Utilizing a marker pen or scribe, mark the mounting holes on the side of the
frame. Use a center punch then drill out the holes to 11/32”. Use the 3/8” x 1” self-tapping bolts
included with the bumper hardware and tighten the winch plate brackets to the frame. Now
tighten the bolts on the other end of the bracket that go through the winch plate.
9. You should now have the winch and fairlead bolted to the bumper, and the bumper securely
installed on the vehicle. Double check that all bolts are properly tightened.
10. Complete the installation by running your winch power and ground cables through the grille and
into the engine bay and connect them to the positive and negative terminals on your battery.
Install your d-ring shackles and winch hook. (if applicable)
If you need further assistance installing your product, please contact us by email at
[email protected] or call us at [phone].
THANK YOU FOR PURCHASING WARRIOR PRODUCTS