Just got my Warn M8000 winch in and I want to install it in my AEV bumper. Problem is the bumper was on the Jeep when I got it and I'm not sure how to take it off. I downloaded the 17 page install manual from AEV's website but it makes it look like the bumper is comprised of a hundred pieces that I would have to remove one by one untill I get to the winch plate. Any suggestions? There has to be a small number of bolts I can remove to make enough of the bumper come loose to allow me access to install the winch, right? Any one know which are the magic bolts?

 

First of all, you're going to want offset wrenches to get to the nuts on the backside...3/4" and 9/16", if I remember correctly. It can be done with regular wrenches and sockets but you'll cuss a lot.

Anyway, you should only need to take the 8 allen heads that are on the face (4 of which hold the fog lights) plus the 4 bolts that hold the bumper on the backside (L-Bracket). Don't take out the large bolts on the L-bracket that tie the bumper to the frame...you want to take the smaller ones that attach to the bumper. A total of 12 bolts and then carefully pull it off straight forward.

I hope this helps...It's hard to describe without pointing at it Now I understand why directions usually don't make sense.

 

Very helpful! I'll see if I can make it all make sense when I'm standing in front of my Jeep again. You're in Omaha, huh? To far for a day trip to come help me out right? lol Thanks for the intel.

 

Ok, thought I was on a roll, got 8 of the 12 bolts out, but there is no way I can get to the nuts on the back of the allen head bolts that hold the fog lights in. I can't break the allen heads from the front. Who ever installed this created one heck of a piece of work. Seriously bent one allen wrench trying to loosen things. The skid plate bolts on the corners won't break either so I can't get it out of the way. Any suggestions?

 

You have the skid as well... OK, you'll need to take the skid completely out of the way. Again, the offset wrench will help.

As far as the allens go, I always use an allen socket on those. It's going to be really hard to get enough torque on it with just an allen wrench...it's a 1/2" bolt with a locking flange nut...it takes a lot of umph.

The "corner" bolts on the skid that are giving you a hard time are a 3/8" self tapper. They're probably just rusted in place but they should break loose with some penetrating oil and some more torque...they are only in by a couple of threads.

It's a great bumper unless you have to put it on, or take it off. AEV was smart to redesign it.

 

Was up till after midnight last night, but after a lot of cussing (I don't have offset wrenches) I finally got the bumper off. My skid plate was mounted with tough nuts and bolts. ? But I sincerely appreciate your words of wisdom, never would have gotten it off without your help! I think I'm going to look for some offset wrenches and socket allen wrenches before trying to button things up today. I had to use lots of WD-40 on the nuts and bolts and used a steel pipe slid over my allen wrench before I got enough torque to break 'em loose. But I'm smiling so far this morning. Thanks again!

 

Offset wrenches and socket hex wrenches= Man's new Best Friend!!!