RR XHD winch solution! No Drilling!
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JK Newbie
Joined: Jun 2007
Posts: 90
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RR XHD winch solution! No Drilling!
I installed my RR XHD modular bumper today and Smittybilt XRC-8 winch. I had heard about the holes being off, but that the nnew batch would be corrected. So I put the winch in the bumper to look at the holes first, and they matched up. I figured I was good to go!
So after installing the fogs, I installed the fairlead and went to install the winch. This is where the problem started. The winch holes no longer matched up! Turns out the bolts for the fairlead got in the way, pushing the winch back so that the holes wouldn't line up. Hopfully, this makes sense the way I described it. Anway, I didn't want to drill, so I went to home depot...
...And bought 3/8" x 1" CARRIAGE bolts. You know, the ones with a slightly rounded top. I also bought nuts, flat washers, and lock washers to go along with it. I was able to bolt the fairlead onto the bumper just by holding the top of the carriage bolt. I may have been able to get them a little tighter if I had a way to hold the top, but I got them pretty tight as is; the lock washers are flat.
As for the winch, it still took some doing, but I was able to get all 4 bolts in. The 2 on the driver's side were no problem but the 2 on the passenger side needed some coaxing. I basically had to use the ratchet to "drive them up in there.
As far as the fairlead is concerned, I feel pretty good with these bolts. They may not be quite as strong as the ones that came with it, but being for the fairlead and not the winch itse;f I think they should be fine, especially if I'm not trying to winch at a 90d angle!
I'll try to get some pics ASAP, but for now just wanted to let you all know how to make it work without drilling and stuff!
So after installing the fogs, I installed the fairlead and went to install the winch. This is where the problem started. The winch holes no longer matched up! Turns out the bolts for the fairlead got in the way, pushing the winch back so that the holes wouldn't line up. Hopfully, this makes sense the way I described it. Anway, I didn't want to drill, so I went to home depot...
...And bought 3/8" x 1" CARRIAGE bolts. You know, the ones with a slightly rounded top. I also bought nuts, flat washers, and lock washers to go along with it. I was able to bolt the fairlead onto the bumper just by holding the top of the carriage bolt. I may have been able to get them a little tighter if I had a way to hold the top, but I got them pretty tight as is; the lock washers are flat.
As for the winch, it still took some doing, but I was able to get all 4 bolts in. The 2 on the driver's side were no problem but the 2 on the passenger side needed some coaxing. I basically had to use the ratchet to "drive them up in there.
As far as the fairlead is concerned, I feel pretty good with these bolts. They may not be quite as strong as the ones that came with it, but being for the fairlead and not the winch itse;f I think they should be fine, especially if I'm not trying to winch at a 90d angle!
I'll try to get some pics ASAP, but for now just wanted to let you all know how to make it work without drilling and stuff!
JK Newbie
Joined: Feb 2008
Posts: 45
Likes: 0
From: Grand Rapids, MI
RR XHD/Warn Fit up
I just installed my RR XHD bumper with a Warn XD9000i winch and had no fit issues. I used the fairlead (and bolts) that came with the winch and the fit was close but everything went together without any issues.
JK Enthusiast
Joined: Apr 2007
Posts: 182
Likes: 0
I had the same problem with my XHD bumper. Only thing is I have a Superwinch so I figured this was the explanation. The tech service at RR assured me the winch would fit in the bumper but the right side of the winch was about 1/2 inch too long. I sawzalled it to make the holes line up. I also had the same problem for the fairlead, I ground the bolts so they would be shorter.