Warn Zeon 10S - Mopar Bumper Warning?

[dajuicejml]

i just got all the necessary parts to complete my winch install in the factory bumper. Opened the winch and had this notice. Anyone know what the additional parts/instructions include??

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[dajuicejml]

I got started anyway but the Zeon is tight. I haven’t mated the bumper back up yet because I still have a few loose ends to tie up first. Just wondering if I’m missing anything? I’m using the JCR winch plate and they provide spacers to lift the Zeon specifically up to where the free spool lever will clear the bumper. Holes lined up so there’s no front to back adjustment. Side to side i just barely was able to get it seated where is was BARELY not touching the frame mount. I did have to cut the factory frame mount to get it this close.

 

[jaydub]

The additional parts listed as required are a new freespool lever, and its installation hardware. The new lever looks identical to the one that the Zeon came with, but only rotates 90˚ to lock/unlock (instead of the stock 180˚). The shorter lever throw makes it easier to clear the bumper. The included installation hardware is new bolts and a new gasket.

I recommend that you call the number Warn provided. They just need your address so they can send the new hardware to you (free of charge). I spoke to a gentleman named Myron when I called, and he was very helpful. I received the new hardware within a couple weeks of calling, and was able to perform the lever switch single handedly. Instructions are included. It was simple but, due to the winch weight and abundance of grease, it was a messy job.

 

[dajuicejml]

The additional parts listed as required are a new freespool lever, and its installation hardware. The new lever looks identical to the one that the Zeon came with, but only rotates 90˚ to lock/unlock (instead of the stock 180˚). The shorter lever throw makes it easier to clear the bumper. The included installation hardware is new bolts and a new gasket.

I recommend that you call the number Warn provided. They just need your address so they can send the new hardware to you (free of charge). I spoke to a gentleman named Myron when I called, and he was very helpful. I received the new hardware within a couple weeks of calling, and was able to perform the lever switch single handedly. Instructions are included. It was simple but, due to the winch weight and abundance of grease, it was a messy job.

Thanks. Were you able to install the part with the winch mounted -OR- did you have to unmount it all together?

 

[jaydub]

I haven’t installed the winch yet... I ordered the Mopar winch plate, but it’s delayed.

You will definitely have to have the winch out to install the new lever though. It requires that you disassemble the winch. You remove the screws from the lever side (i.e. right-hand side), and pull that entire half off. It was a bit intimidating, as you see the winch gears in all their glory. In a nutshell, you pull the lever side off, unscrew/remove the stock lever, put the new lever in, then push the side back on. The trickiest part was lining up the gears so that the side could slide all the way back in. It took a couple of tries for me to get it. As I mentioned in my previous post, there is a lot of thick grease in there, so it’s a nasty job. Warn includes a new gasket to seal the side when you reassemble it. I certainly needed it, as I tore the stock gasket during disassembly. I forgot to mention that Warn also sends new stickers labeling the 90˚ turn to disengage. They are direct replacements for the two stickers that came on the winch (surrounding the lever), just providing revised instructions on how to disengage/engage.

If you’re pondering finishing the install now versus waiting for the new lever and redoing everything... I think it comes down to how comfortable you are with the existing 180˚ lever throw. If it clears the bumper enough for your liking now (with the JCR winch plate with spacers), then you can probably proceed with what you’ve got. If it’s too tight (or you’d just rather be able to disengage with a 90˚ turn), then you might want to wait for the hardware from Warn. My predicament (not having a winch plate yet) made my decision easy.

 

[CrazyKASG]

Just finished install with the JCR bracket today. Was expecting it to fit, but the winch guard stops the free spool. Wish I would have seen this first! Those bolts are a huge pain to get at!

 

[dajuicejml]

Finished mine today and the spool lever barely clears to full unlock. I was able to get 7 of the 8 nuts back on the factory bumper mounts, but there was 1 where the winch simply was too close to the bolt. It left maybe enough clearance to get a regular but, but the factory ones have that washer like flare on the back that simply was too large to get started. I’ll try to get a slimmer but at Lowe’s and see if that works.

Overall I would say that the winch looks great and will function 100%, BUT it’s likely a call as to whether you prefer an easy install by going w something smaller OR a PITA install to get the big boy.

 

[agordon117]

Is there not enough clearance towards the grill to just rotate the lever 90 degrees towards the rear of the vehicle? Or 72 degrees I guess based on the 5 bolt pattern? Really going to be bummed if I have to wait on Warn to send parts out to install this.

Did they need a serial number or anything to send the parts? I haven't received my winch yet and would like to get things moving sooner than later.

 

[jaydub]

I can’t recall if I had to provide the serial number when I spoke to Warn. It wouldn’t hurt to call the number (provided in the attached image in the original post) and discuss it. If you bought a Zeon, I would bet that you’ll get some latitude from them regarding sending the new lever.

 

[jaydub]

This is my Zeon 10S with the new lever installed (freespooled). It also has the new stickers applied.

 

[bdog]

Looks like Warn has a mounting plate for the JL factory steel bumper now.
https://www.quadratec.com/p/warn/winch-mount-plate-jeep-wrangler-jl-factory-steel-bumper

 

[Firecracker Rubi]

If you call the right shop, you can order it with the new clutch handle already installed from Warn.



River City Off-road got one for me shipping today. They went in to production today as well, call Marcus and avoid messing with changing the lever out.

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