Warn 61854, 61857, 61860 Installation Instructions Manual

INSTALLATION INSTRUCTIONS

FOR JEEP REAR BUMPERS

TJ P/N 61854, YJ P/N 61857,

CJ P/N 61860

Y our safety , and the safety of others, is very important. T o 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 identifies 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.

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.

 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.

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 . B1PAGE 1

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.

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. g 12900 SE CAPPS ROAD g CLACKAMAS, OR 97015-8903

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g CUSTOMER SERVICE LINE 1-888-722-6730

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© 2005 Copyright Warn Industries, Inc. All right s reserved.

WARN INDUSTRIES 62060 Rev . B1PAGE 2