WESTiN 2404185 Hidden Winch Mount Installation Guide

WESTiN 2404185 Hidden Winch Mount

Product Information

• Application: 2022-2023 Ford Bronco (Excl. Bronco Sport)
• Part Number: 2404185

Product Usage Instructions

Tools Needed

• Torque wrench
• 10mm, 17mm, 19mm sockets
• Allen wrench
• Ratchet
• Hose clamp

Installation Procedure

1. Remove contents from the box and ensure all parts are present and undamaged.
2. Read and understand all instructions before starting the installation.
3. Remove the factory skid plate.
4. If applicable, remove the cooler from the frame.
5. Cut the frame extensions off of the frame and ensure a smooth surface where they were cut.
6. Trim the feet that attached the cooler to the top of the frame if applicable.
7. Clamp the hoses attached to the cooler.

Note:
Anti-seize lubricant must be used on all stainless steel fasteners to prevent thread damage and galling.

FAQ

• Q: What should I do if I encounter missing or damaged parts during installation?
  A: Contact Customer Service at 800-793-7846 for assistance with missing or damaged items.

• Q: Can I install this product on a Bronco Sport model?
  A: No, this product is not compatible with the Bronco Sport model.

Parts Description

• APPLICATION: 2022-2023 Ford Bronco (Excl. Bronco Sport)
• PART NUMBER: 2404185

ANTI-SEIZE LUBRICANT MUST BE USED ON ALL STAINLESS STEEL FASTENERS TO PREVENT THREAD DAMAGE AND GALLING

INSTALLATION PROCEDURE

1. Remove contents from the box, and verify if all parts listed are present and free from damage. Carefully read and understand all instructions before attempting installation. Failure to identify damage before installation could lead to a rejection of any claim.

2. Remove the factory skid plate.

3. If equipped, remove the cooler from the frame.

4. Cut the frame extensions off of the frame. Make sure that the surface of the frame is smooth where the frame extensions were cut. See Figure 1.
   For V6 models with a transmission cooler, follow Steps 5-22. For models without a transmission cooler, skip to Step 23.

5. Trim the feet that attached the cooler to the top of the frame off of the transmission cooler. See Figure 2.

6. Clamp the two black hoses attached to the cooler. See Figure 3.

7. Disconnect the passenger-side black hose from the cooler. See Figure 4.

8. Trim the passenger side black hose 5.25 inches. See Figure 4.

9. Reconnect the passenger side black hose to the fitting using the included hose clamp (item 15).

10. Route the passenger-side black hose over the driver-side hoses and reconnect it to the transmission cooler. See Figure 4.

11. Disconnect the long upper hose from the coolant pump. See Figure 5.

12. Trim 5 inches from the hose disconnected in the previous step. See Figure 5.

13. Reconnect the hose to the coolant pump. See Figure 5.

14. Remove the clamp from the hoses.

15. Attach the coolant pump to the coolant pump bracket (item 13) using the M6 hardware (items 27, 28, 30, 31). See Figures 6 and 7. Tighten M6 hardware to 7-8 ft-lbs.

16. Attach the coolant pump bracket to the vehicle frame using the M8 hardware (items 32, 35, 36). See Figures 6 and 7. The coolant pump bracket will fit over the hose shown in Figure 6. Tighten M8 hardware to 15-18 ft-lbs.

17. Attach Cooler Bracket ’A’ (item 11) vehicle frame using the M8 Hex hardware (items 34-36) and OEM hardware. Tighten M8 hardware to 15-18 ft-lbs. See Figures 8 and 9.

18. Attach the transmission cooler to Cooler Bracket ‘B’ (item 12) using the M6 hardware (items 28, 29, 31, 38). See Figure 10. Tighten M6 hardware to 7-8 ft-lbs.

19. Zip-tie the transmission cooler hoses to keep the hoses away from moving engine components. See Figure 11.

20. Attach Cooler Bracket ‘B’ (item 12) to Cooler Bracket ‘A’ using the M8 hardware (items 22-25). Tighten M8 hardware to 15- 18 ft-lbs. See Figure 12.

21. Check the transmission cooler hoses to make sure that they are clear of all moving engine components. Use additional zip ties if needed.

22. Attach the brake line to Cooler Bracket ‘B’ using the M6 hardware (items 26, 28, 30, 31) and the loop clamp (item 14). See Figure 13. Tighten M6 hardware to 7-8 ft-lbs.

23. Pull and twist the SX winch clutch handle so that the clutch is in the free spool position. See Figure 14.

24. Stand the winch up onto the motor cover. See Figure 15.

25. Remove the (4) M8 bolts attaching the tie bar to the gearbox and motor end of the winch to the tie bar and remove gearbox end. See Figure 16.

26. Remove the gearbox assembly and tie bar from the winch.

27. Remove the eight bolts that attach the gearbox to the drum support. See Figure 17.

28. Rotate the gearbox to the position shown in Figure 18.

29. Replace the eight bolts that attach the gearbox to the drum support.

30. Torque M5 bolts in a star pattern to 50-55 in-lb. See Figure 19.

31. Place the gearbox assembly onto the winch. Ensure the drive shaft and drum properly engage the gearbox. Rotate the gearbox assembly as necessary to engage the gearbox.

32. Install the tie bar. Torque the M8 tie bar bolts to 18 ft-lbs.

33. Disconnect the original cables from the motor.

34. Install (1) yellow terminal boot onto each end of the 6-foot long Motor Cable “A”.

35. Install (1) red terminal boot onto each end of the 6-foot long Motor Cable “B”.

36. Install (1) black terminal boot onto each end of the 6-foot long Motor Cable “C”.

37. Install Motor Cable “A” with the yellow terminal boot onto the yellow motor terminal. See Figure 20.

38. Install Motor Cable “B” with the red terminal boot onto the red motor terminal. See Figure 20.

39. Install Motor Cable “C” with the black terminal boot onto the black motor terminal. See Figure 20.

40. Install the black ground cable included with the SX winch onto the motor ground terminal. See Figure 20.

41. Remove the control box from the winch.

42. Disconnect the drum light cable. See Figure 21.

43. Attach the 6-foot-long drum light cable (item 9) to the drum light cable on the winch.

44. Install the winch onto the winch tray using the hardware included with the winch. See Figures 22-23.

45. Remove the brackets shown in Figure 24. If equipped, remove the tow hooks. The tow hooks will be reused.

46. Route the winch cables upwards towards the engine bay.

47. Install the winch tray (item 1) onto the frame using the M12 hardware (items 16-18). Start by loosely installing the (2) back M12 bolts. Start reinstalling the OEM brackets by placing them under the winch tray so that they are aligned with the (2) holes in the frame that they were originally attached to. Slide the OEM brackets between the winch tray and the M12 flat washer. Install (1) spacer plate (item 4) on each side in the location shown in Figure 24. Install the (2) front M12 bolts through the OEM bracket and winch tray. Tighten the M12 hardware to 50-55 ft-lbs. See Figure 25.

48. Remove the front bumper.

49. Remove the plastic part shown in Figure 26.

50. Trim the plastic part as shown in Figure 27.

51. Reinstall the plastic part and front bumper.

52. Loosely install the skid plate (item 2) to the vehicle using the M10 hardware (items 19-21). See Figures 27 and 28.

53. Loosely install the skid plate to the winch tray using the M8 hardware (items 32, 33, 35, 36, 37). See Figure 29.

54. If an optional cover panel (item 3) is installed, use the M6 hardware (items 26, 28, 30). See Figure 30.

55. Tighten hardware to the following specifications: Tighten M6 hardware to 7-8 ft-lbs, M8 hardware to 15-18 ft-lbs, and M10 to 35 ft-lbs.

56. Route the yellow, red, and black motor cables towards the location shown in Figure 31.

57. Route the drum light cable toward the location shown in Figure 31.

58. Remove the control box lid.

59. Install the motor cables and 8-foot-long power cable onto the contactor according to Figure 32. Tighten the M8 hardware to 15-18 ft-lbs.

60. Reinstall the control box lid.

61. Attach the 6-foot-long drum light cable to the control box drum light cable.

62. Attach the control box to the control box bracket (item 5) using the M5 hardware (items 39 and 40). See Figure 33.

63. Attach the control box bracket to the vehicle using the M6 hardware (items 26, 28, 30, 31). Tighten the M6 hardware to 7-8 ft-lbs. See Figures 31 and 33.

64. Install the small control box ground cable eyelet to the vehicle. See Figure 31.

65. Route the black ground cable and 8-foot-long power cable toward the vehicle battery.

66. Connect the black ground cable to the battery ground terminal.

67. Connect the 8-foot long power cable to the battery-positive terminal.

WARNING

Failure to follow these instructions could lead to death, personal injury, and/or property damage.

Failure to follow these instructions could lead to death, personal injury, and/or property damage.

• FASTENERS:
  All Westin-supplied fasteners must be utilized and installed per the installation in-structions and apply torque to the specifications as defined. DOUBLE CHECK ALL FASTENERS BEFORE INITIAL USE, AND PERIODICALLY IN THE FUTURE TO ENSURE PROPER FUNCTION AND SAFETY.

• DRILLING:
  Most Westin products do not require drilling for installation. If drilling is defined as required, use caution when drilling a vehicle. FAILURE TO REVIEW AN AREA TO BE DRILLED MAY RESULT IN PERSONAL INJURY AND/OR INJURY TO OTHERS AS WELL AS VEHICLE DAMAGE.

• EYE PROTECTION:
  ALWAYS WEAR SAFETY GLASSES OR GOGGLES DURING THE INSTALLATION PROCESS TO AVOID PERSONAL INJURY.

• MAXIMUM TOWING/CARRYING CAPACITY: (if applicable)
  The Westin Receiver Hitches will have a visible tow rating label affixed directly on the product. Users should never exceed the vehicle manufacturer’s maximum tow and weight rating regardless of the capacity of the hitch. FAILURE TO FOLLOW THESE GUIDELINES WILL VOID THE WESTIN WARRANTY AND MAY RESULT IN PERSONAL INJURY AND/OR INJURY TO OTHERS AS WELL AS VEHICLE DAMAGE.

• FOR CALIFORNIA RESIDENTS ONLY 65 WARNINGS:
  Some products may contain chemicals such as DEHP, which can cause cancer, birth defects, or other reproductive harm. For more info go to www.p65warnings.ca.gov.

Westin Automotive Products, Inc. 320 W. Covina Blvd San Dimas, CA. 91773

Thank you for choosing Westin products for additional installation assistance please call Customer Service at 800-793-7846 at www.westinautomotive.com.

References

• p65warnings.ca.gov

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