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Old 01-30-2021, 02:54 PM #1
Draggin Draggin is offline
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Join Date: Dec 2015
Location: Sedona (VOC)
Posts: 86
Real Name: Ken
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Draggin Draggin is offline
Member
 
Join Date: Dec 2015
Location: Sedona (VOC)
Posts: 86
Real Name: Ken
Draggin is on a distinguished road
SSO Hybrid Bumper + Warn M8000 winch install

Hey all

Thought I would share some details on the SSO Hybrid install with Warn M8000. Overall the bumper fit very well and was easy to cut/install the plastic off the stock bumper to make it fit. A friend more capable than I was required =).

Removing the bumper was pretty simple and we just followed overland wanderlusts's directions on their video How To Install Slimline Steel Front Bumper on 5th Gen 4Runner - YouTube

Next step was to test fit the bumper in place and to get an idea of how much space was available for the Warn M8000 winch. Once in place the AC line was clearly in the way and the control pack needed to be located. I'd seen pictures of people doing a metal plate over the radiator, but it would be hard to reach to plug the controller

Looking around the engine bay we decided to place it behind the fuse box . My friend was able to fab (cut and bend) a metal plate from Ace hardware to specs and use two existing threaded holes in the side panel. We also painted this with a hammer finish spray paint. The plate does give but the cables coming down give some support as well. The fuse panel lid can still come off but takes some careful persuasion to clamp back on but still does. May need to change this but it holds pretty well. The controller is in a much more reachable place vs feeling around in the dark where the winch is.

We had to replace the existing wires with 2 gauge wire and terminals at about 5-6' for each of the three lines. The control pack disassembled pretty easily. We had a specific crimper for larger copper terminals that was very helpful. Finding 2 gauge wire and then the terminals required 5 stores in the greater phoenix area. Three of which were just for the terminal size gauge and post fitment. Got some color coded vinyl tap to ensure we didn't get the wires crossed. The wires come down from the battery and then across to the winch connectors with some wire loom in two places to keep things from rubbing on metal edges.

When putting back the plastic bumper the air dams for the radiator did not want to fit with the new bumper on the driver side. So we cut away until they did. The directions from wanderlust overland you tube video took them off altogether but we didn't like that idea.

The Heise light bar (30") install with rigid wiring harness was mostly straight forwards except the skinny nut for the bolt required some low profile box wrenches. The space between the metal bracket and side of the bumper is very narrow. Luckily cheaper Ace hardware ones did the trick as you aren't going to find those in a box store. Of course I had to get a set of those vs just the 13mm I needed. I almost returned them after the job.

Getting through the firewall for the switch install is always an exercise in patience and contortion of which my friend greatly helps. We cut through a boot where the ebrake cable runs near the driver side floor/fuse panel and had put the air compressor through. I used an Air onboard switch to plug it in next to the interior light dimmer where I had a blank. The switches are nice and you can get whatever pic you want. We used a coat hanger to feed the wire up into the dash and didn't need to pull any panels.

When we went to aim the light bar the air damn on the passenger? side was blocking that damn skinny nut so we had to get out the clippers and cut more away to get access. Kind of a bother but not much had to be removed and now I can still aim the lights.

The install was likely 8 hours with 2 more hours driving around looking for parts. Not really difficult save the bracket which I knew I would need help with and then just time and patience.

This is the crimper that made the wire replacement soooooo much easier. Pliers just don't do a good job of holding.
TEMCo Hammer Lug Crimper Tool
Air On Board Switches
Attached Images
SSO Hybrid Bumper + Warn M8000 winch install-01-before-jpg  SSO Hybrid Bumper + Warn M8000 winch install-02-no-bumper-jpg  SSO Hybrid Bumper + Warn M8000 winch install-04-new-controller-location-jpg  SSO Hybrid Bumper + Warn M8000 winch install-05-quick-fab-jpg  SSO Hybrid Bumper + Warn M8000 winch install-06-bumper-back-jpg  SSO Hybrid Bumper + Warn M8000 winch install-07-control-place-jpg  SSO Hybrid Bumper + Warn M8000 winch install-09-across-winch-jpg  SSO Hybrid Bumper + Warn M8000 winch install-10-done-jpg 
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