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©2017 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.

 1 

105714A0

WARN INDUSTRIES, INC.

 12900 S.E. Capps Road,

Clackamas, OR USA 97015-8903, 1-503-722-1200, FAX: 1-503-722-3000

Customer Service:

 1-800-543-9276

Dealer Locator Service:

 1-800-910-1122

International Fax:

 1-503-722-3005

INSTALLATION INSTRUCTIONS

SEMI HIDDEN KIT

Part Number: 103209

Application: 2014+ Toyota Tundra

G E N E R A L   S A F E T Y   P R E C A U T I O N S

  

  W A R N I N G

IMPACT AND MOVING PARTS ENTANGLEMENT HAZARD

Failure to observe these instructions could lead to severe injury or death

•  Always 

take time to fully read the Instructions and/or Operations Guide, and/or Basic Guide to Winching Techniques, in order to understand your winch and its operations.

•  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.

•  Never

 lean over battery while making connections.

•  Never

 route electrical cables:

  o  Across any sharp edges.
  o  Through or near moving parts.
  o  Near parts that become hot.

•  Always

 insulate and protect all exposed wiring and electrical terminals.

•  Always

 install terminal boots as directed in installation instructions.

•  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.

•  Always

 perform regular inspections and maintenance on the plow mechanism, fasteners, cable and related hardware.

•  Always

 replace all worn or damaged parts before operating.

•  Never

 operate this WARN product with damaged or missing parts.

Read installation and operating instructions thoroughly.

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.

Summary of Contents for 103209

Page 1: ...electricalterminals Alwaysinstallterminalbootsasdirectedininstallationinstructions Alwaysuseappropriateandadequatecareinliftingcomponentsintoplace Alwaysinsurecomponentswillremainsecureduringinstallationandoperation Alwaystightenallnutsandboltssecurely pertheinstallationinstructions Alwaysperformregularinspectionsandmaintenanceontheplowmechanism fasteners cableandrelatedhardware Alwaysreplaceallwo...

Page 2: ...cifications page 2 Parts List page 3 Installation page 4 8 Maintenance Care page 8 T O O L S R E Q U I R E D Standard wrenches Standard sockets Reciprocal saw or other cutting tool B E F O R E Y O U B E G I N N O T I C E This product may interfere with driver assist systems such as adaptive cruise control and parking assist systems that have sensors or cameras installed in the bumpers or front gri...

Page 3: ... Inc 3 105714A0 P A R T S L I S T ITEM PART NO DESCRIPTION QTY 1 103206 LH BUMPER BRACKET 1 2 103195 RH BUMPER BRACKET 1 3 102846 SEMI HIDDEN WELDMNT 1 ITEM PART NO DESCRIPTION QTY 4 83125 M6 X 1 0 NUT 2 5 64108 M6 1 0 x 25 BOLT 2 6 102248 BLACK PLASTIC PLUG not shown 2 2 1 3 4 5 ...

Page 4: ...m socket remove grille by removing the four front center screws as well as the two outer push pins 2 Remove one plastic clip from fender liner both sides 3 Using a 17mm socket remove the two bolts securing the tow hook each side Remove tow hook and set aside Save tow hook and bolts for reuse Figure 1 Figure 2 Figure 3 Plastic clips 10mm bolts Plastic clip ...

Page 5: ...upcoming installation 5 From underneath the bumper use a 14mm socket to remove the four nuts each side holding the bumper structure to the frame rails Save nuts for reuse 6 If equipped disconnect harness from rear of fog lamps and disconnect park sensor harness both sides WARNING Always use assistance when moving or lifting heavy parts 6 Remove and set aside bumper Figure 5 Figure 6 Figure 4 ...

Page 6: ...using the six reinforcement bar nuts 12 From the outside of the bumper use a reciprocating saw or similar tool to carefully cut out the center plastic following styling lines Tip Mask cut lines to prevent unnecessary damage NOTE Relocating the control pack can be done to avoid next step For winches with top mounted control pack only 13 From the inside of the bumper carefully cut a 10 x 2 inch sect...

Page 7: ...ing instructions 16 Mount the winch to the semi hidden weldment according to your winch mounting instructions WARNING Always use assistance when moving or lifting heavy parts 17 With assistance place bumper in position on vehicle Do not install nuts yet 18 Before installing the semi hidden weldment winch assembly route the winch power cables through the cutout in the bumper and in front of the rad...

Page 8: ...commend using a floor jack to help with this 24 Now that all the hardware is installed a Check to make sure that there isn t to much space between the frame brackets and the bumper b Confirm bumper is centered and aligned vertically and horizontally c Once satisfied with alignment torque all hardware to suggested values on page 2 NOTE Always make adjustments with assistance 25 Installation is now ...

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