Anyone else have problems with Warn bumper?
Thread Starter
JK Enthusiast
Joined: Apr 2007
Posts: 116
Likes: 0
From: Phoenix, AZ
Anyone else have problems with Warn bumper?
I recently got the Warn Rockcrawler front bumper & Dual Force winch for my 07 Unlimited.
Well, there's 8 bolt holes in the Jeep's front tabs which are mounted to the frame. When puting on the bumper, you slide the bolts through these holes & screw them into the 8 pre-welded & pre-tapped screws which are mounted to the bumper.
Of these 8 screws, 2 were not tapped/threaded correctly & the bolts absolutely would not screw in. The two screws were the inside, lower screws..one on either wide.
Soooo.....off came everything. The thread pattern is 7/16 with 14 threads per inch...which, of course, Home Depot doesn't carry in a tap and..as usual...it was closing time. However, I was eventually able to find an Ace with the right tap.
When I ran the tap into the holes, it wasn't even close....there were threads in these two holes, but not even near what needed to be.
Once the bumper was installed, I put the winch plate on and....as my luck goes....none of the 6 holes which you would mount the "push bar/pull bar" to lined up...
Basically, these had to line up because, as in the case of the frame tabs, the screws were welded in the actual bumper, so alignment had to be right on.
Anyway, everything ended up ok after an hour of a Dremel grinder on these holes....but, come on Warn! How did this stuff pass quality control?????
I'm not sure who Warn has checking this stuff, but it needs to be addressed. This kind of thing can hurt the bottom line if left unchecked.
Has anyone else had this problem?
PS...the Dual Force winch is the set up to have & works great. I just hope different quality control oversaw the winch making than who was in charge of the bumpers!
Well, there's 8 bolt holes in the Jeep's front tabs which are mounted to the frame. When puting on the bumper, you slide the bolts through these holes & screw them into the 8 pre-welded & pre-tapped screws which are mounted to the bumper.
Of these 8 screws, 2 were not tapped/threaded correctly & the bolts absolutely would not screw in. The two screws were the inside, lower screws..one on either wide.
Soooo.....off came everything. The thread pattern is 7/16 with 14 threads per inch...which, of course, Home Depot doesn't carry in a tap and..as usual...it was closing time. However, I was eventually able to find an Ace with the right tap.
When I ran the tap into the holes, it wasn't even close....there were threads in these two holes, but not even near what needed to be.
Once the bumper was installed, I put the winch plate on and....as my luck goes....none of the 6 holes which you would mount the "push bar/pull bar" to lined up...
Basically, these had to line up because, as in the case of the frame tabs, the screws were welded in the actual bumper, so alignment had to be right on.
Anyway, everything ended up ok after an hour of a Dremel grinder on these holes....but, come on Warn! How did this stuff pass quality control?????
I'm not sure who Warn has checking this stuff, but it needs to be addressed. This kind of thing can hurt the bottom line if left unchecked.
Has anyone else had this problem?
PS...the Dual Force winch is the set up to have & works great. I just hope different quality control oversaw the winch making than who was in charge of the bumpers!
JK Enthusiast
Joined: Feb 2007
Posts: 185
Likes: 0
From: Upstate SC
I had to knock a couple of beads out of my threads, but nothing as bad as what it sounds like you had to deal with. I really liked the instructions with my dual force hd that had no torque specs at all...
Last edited by russredx; Aug 23, 2007 at 06:46 PM.
JK Freak
Joined: Aug 2007
Posts: 665
Likes: 0
From: (714)
I recently got the Warn Rockcrawler front bumper & Dual Force winch for my 07 Unlimited.
Well, there's 8 bolt holes in the Jeep's front tabs which are mounted to the frame. When puting on the bumper, you slide the bolts through these holes & screw them into the 8 pre-welded & pre-tapped screws which are mounted to the bumper.
Of these 8 screws, 2 were not tapped/threaded correctly & the bolts absolutely would not screw in. The two screws were the inside, lower screws..one on either wide.
Soooo.....off came everything. The thread pattern is 7/16 with 14 threads per inch...which, of course, Home Depot doesn't carry in a tap and..as usual...it was closing time. However, I was eventually able to find an Ace with the right tap.
When I ran the tap into the holes, it wasn't even close....there were threads in these two holes, but not even near what needed to be.
Once the bumper was installed, I put the winch plate on and....as my luck goes....none of the 6 holes which you would mount the "push bar/pull bar" to lined up...
Basically, these had to line up because, as in the case of the frame tabs, the screws were welded in the actual bumper, so alignment had to be right on.
Anyway, everything ended up ok after an hour of a Dremel grinder on these holes....but, come on Warn! How did this stuff pass quality control?????
I'm not sure who Warn has checking this stuff, but it needs to be addressed. This kind of thing can hurt the bottom line if left unchecked.
Has anyone else had this problem?
PS...the Dual Force winch is the set up to have & works great. I just hope different quality control oversaw the winch making than who was in charge of the bumpers!
Well, there's 8 bolt holes in the Jeep's front tabs which are mounted to the frame. When puting on the bumper, you slide the bolts through these holes & screw them into the 8 pre-welded & pre-tapped screws which are mounted to the bumper.
Of these 8 screws, 2 were not tapped/threaded correctly & the bolts absolutely would not screw in. The two screws were the inside, lower screws..one on either wide.
Soooo.....off came everything. The thread pattern is 7/16 with 14 threads per inch...which, of course, Home Depot doesn't carry in a tap and..as usual...it was closing time. However, I was eventually able to find an Ace with the right tap.
When I ran the tap into the holes, it wasn't even close....there were threads in these two holes, but not even near what needed to be.
Once the bumper was installed, I put the winch plate on and....as my luck goes....none of the 6 holes which you would mount the "push bar/pull bar" to lined up...
Basically, these had to line up because, as in the case of the frame tabs, the screws were welded in the actual bumper, so alignment had to be right on.
Anyway, everything ended up ok after an hour of a Dremel grinder on these holes....but, come on Warn! How did this stuff pass quality control?????
I'm not sure who Warn has checking this stuff, but it needs to be addressed. This kind of thing can hurt the bottom line if left unchecked.
Has anyone else had this problem?
PS...the Dual Force winch is the set up to have & works great. I just hope different quality control oversaw the winch making than who was in charge of the bumpers!