WARN TJ P-N 61854 Rock Crawler Rear Bumper Installation Guide

: June 15, 2024
: WARN

Table of Contents

WARN TJ P-N 61854 Rock Crawler Rear Bumper
Product Information
Product Usage Instructions
INSTALLATION
Contacts
Read User Manual Online (PDF format)
Download This Manual (PDF format)

WARN TJ P-N 61854 Rock Crawler Rear Bumper

WARN-TJ-P-N-61854-Rock-Crawler-Rear-Bumper-PRODUCT

Product Information

Specifications

TJ P/N: 61854
YJ P/N: 61857
CJ P/N: 61860

Frequently Asked Questions

What should I do if my TJ model vehicle does not have all 8 mounting locations on the rear frame area?
- If all 8 mounting locations are not present on the frame, measure the supplied bumper mounting points and match these measurements on the frame. Then, drill the frame holes to 7/16 according to the provided instructions.
What should I do if I encounter any difficulties during installation?
- If you encounter any difficulties during installation, please contact our customer service line at 1-888-722-6730 for assistance.

Product Usage Instructions

Safety Precautions

Before installing and operating the Jeep Rear Bumpers, it is important to follow these safety precautions:

Always use extreme caution when drilling on any vehicle. Ensure that all fuel lines, brake lines, electrical wires, and other objects are not punctured or damaged during the drilling process. Thoroughly inspect the area to be drilled on both sides of the material and relocate any objects that may be damaged. Failure to inspect the area may result in vehicle damage, electrical shock, fire, or personal injury.
Always wear safety glasses when installing the kit to protect against flying metal chips that can cause eye injury.
Exercise extreme caution when cutting and trimming during fitting. Remove jewellery and wear eye protection.
Use appropriate and adequate care when lifting components into place.
Ensure that all components are securely fastened during installation and operation.
Tighten all nuts and bolts securely according to the installation instructions.

Installation Process:

Step 1: Remove the rear bumper from the vehicle.
- Follow the appropriate procedures to safely remove the existing rear bumper from your vehicle.
Step 2: Install the new Warn rear bumper on the vehicle.
- Follow the provided installation instructions to securely install the new rear bumper on your vehicle.

Note: For some TJ and YJ models, it may be necessary to loosen the gas tank skid plate to access the inner bolt hole locations.

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 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.

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

INSTALLATION

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.
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.
- 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.