WARN 107168 Hidden Winch Mounting Kit Instruction Manual

Introduction

This instruction manual provides detailed guidance for the installation, operation, and maintenance of the WARN 107168 Hidden Winch Mounting Kit. This kit is specifically designed for Ford Super Duty (2020) vehicles, allowing for the integration of a winch while maintaining the factory bumper's appearance. The system utilizes existing factory frame holes for a secure fit and positions the winch discreetly behind the bumper, with controls accessible from the top.

Important Safety Information

Read and understand all instructions and warnings before installing or operating this product. Failure to follow these instructions may result in serious injury, property damage, or product malfunction.

• Always wear appropriate personal protective equipment (PPE), including safety glasses, gloves, and hearing protection, during installation.
• Ensure the vehicle is securely supported on a level surface before beginning any work. Disconnect the vehicle's battery to prevent accidental electrical discharge.
• Do not modify the mounting kit or vehicle components. Modifications can compromise safety and performance.
• Verify all fasteners are tightened to the manufacturer's specified torque values.
• If you are unsure about any part of the installation process, seek assistance from a qualified professional.

Package Contents

Carefully unpack all components and verify that all items listed below are present. If any parts are missing or damaged, contact WARN customer support immediately.

Image: All components of the WARN 107168 Hidden Winch Mounting Kit, including main bracket, side supports, various fasteners, and wiring for winch control access.

• Main Winch Mounting Plate
• Left and Right Frame Mounting Brackets
• Support Brackets (various sizes)
• Hardware Kit (bolts, nuts, washers, lock washers)
• Winch Control Access Wiring/Harness
• Cable Ties
• Instruction Manual (this document)

Tools Required

The following tools are typically required for the installation of the WARN 107168 Hidden Winch Mounting Kit:

• Standard Socket Set and Wrenches
• Torque Wrench
• Drill and Drill Bits (if specified in detailed instructions, not explicitly stated here but common)
• Cutting Tools (e.g., utility knife, if bumper trimming is required)
• Measuring Tape
• Marker or Scribe
• Personal Protective Equipment (PPE)

Setup and Installation

The WARN 107168 Hidden Winch Mounting Kit is designed for a precise fit on Ford Super Duty (2020) models. The installation process involves mounting the winch behind the factory bumper, utilizing existing frame holes.

Image: The WARN 107168 Hidden Winch Mounting Kit, showing the main mounting plate and support brackets, designed for discreet winch installation.

General Installation Steps:

1. Prepare Vehicle: Park the vehicle on a level surface, engage the parking brake, and disconnect the battery. Remove any necessary front bumper components as per vehicle-specific instructions.
2. Mount Frame Brackets: Attach the left and right frame mounting brackets to the vehicle's factory frame holes. Ensure proper alignment and hand-tighten fasteners.
3. Install Winch Mounting Plate: Secure the main winch mounting plate to the frame brackets. This plate will house the winch.
4. Install Winch: Mount your compatible winch onto the winch mounting plate according to the winch manufacturer's instructions.
5. Reinstall Bumper: Reattach the factory bumper. Note that the bumper will extend out approximately 8 inches from its original position.
6. Address Gaps (Optional): If desired, fill any resulting gaps in the bumper area with a Skirting Kit (sold separately) for a finished appearance.
7. Connect Winch Controls: Route the winch control wiring to allow access through the designated opening on the top of the bumper, as specified by the kit design.
8. Final Tightening: Once all components are in place and aligned, torque all fasteners to the specifications provided in the detailed WARN installation guide (not included in this general manual).
9. Reconnect Battery: Reconnect the vehicle battery and test the winch functionality.

Note: This manual provides general installation steps. Always refer to the detailed, vehicle-specific installation instructions provided by WARN with your product for precise torque specifications and component placement.

Operating the Winch (Post-Installation)

Once the WARN 107168 Hidden Winch Mounting Kit is installed and a compatible winch is secured, the winch's operation will follow its manufacturer's instructions. This mounting kit facilitates discreet winch placement and provides access to controls.

• Ensure the winch controls are easily accessible through the designated opening on the top of the bumper.
• Always follow the safety guidelines and operating procedures outlined in your winch's instruction manual.
• Regularly inspect the winch line, fairlead, and all connections before and after each use.

Maintenance

Proper maintenance of your WARN Hidden Winch Mounting Kit ensures its longevity and reliable performance.

• Regular Inspection: Periodically inspect all mounting bolts and fasteners for tightness. Re-torque as necessary, especially after initial installation and heavy use.
• Corrosion Prevention: Keep the mounting kit clean from dirt, mud, and road salt. Wash with mild soap and water, then rinse thoroughly. Apply a protective coating or wax to exposed metal surfaces to prevent corrosion.
• Damage Check: Inspect the brackets and mounting plate for any signs of damage, cracks, or deformation. If damage is found, discontinue use and replace affected components immediately.

Troubleshooting

This section addresses common issues that may arise with the WARN 107168 Hidden Winch Mounting Kit. For winch-specific issues, refer to your winch's instruction manual.

If you encounter issues not listed here or require further assistance, please contact WARN customer support.

Specifications

Warranty and Customer Support

For information regarding the warranty of your WARN 107168 Hidden Winch Mounting Kit, please refer to the warranty documentation included with your purchase or visit the official WARN website. For technical assistance, missing parts, or any other inquiries, please contact WARN customer support directly.

WARN Official Website: www.warn.com