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Old 03-31-2010, 08:38 PM   #1
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Warn rear bumper/tire carrier help.....

So ordered my Warn rear bumper and tire carrier. Cool, right? I thought so....at least until I saw the directions. They are nothing short of incredibly bad.

Anyway, got the additional inside holes drilled in the rear of the frame (for the 4 extra bolts). Now that I have the holes drilled, how the @#$% do I reach in there and bolt them in?!? Remove the gas tank? I was able to lower it a little bit (maybe an inch) and still couldnt get my hands in there.

Gave up on those for the time being and bolted up the rest of it......and broke one of the outside bolts off in the bumper. Broke two extractors trying to get the remnants out, so its pretty well stuck in there. I have the bumper on with just 5 bolts right now - the 2 underneath (1 on each side), and the 3 bolts that fit parallel to the road (2 on pass side, 1 on drivers side). Its plenty solid for carrying the tire I think.

My worry is the strength and will it hold up in the event that I attempt to tow someone or get towed out myself. I have fri off and plan to try the inside bolts again, assuming I can do something more with the gas tank and skid (nothing after-market under there). Other alternative I think is to buy a welder (kinda sounds like a fun/cool idea anyway) and weld the sob on. Then of course Im sol if I ever need to get the bumper off though.

Thoughts? Suggestions? Instructions on how to lower the gas tank? Pretty well stuck at the moment so anything helps.

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Old 03-31-2010, 09:23 PM   #2
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You story sounds like every part I have tried to install on my jeeps... something always go's to hell. Though for the bumper I had with frame tie in's I didn't have to drop the tank.. I recall the brackets made use of hole in the frame and I think I had to drill 2 holes.

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Old 03-31-2010, 09:40 PM   #3
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Quote:
You story sounds like every part I have tried to install on my jeeps... something always go's to hell.
Haha couldnt have said it better. Somehow though, I never seem to learn. I keep trying, one day something has to go smoothly, right?
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Old 03-31-2010, 09:55 PM   #4
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Sorry can't offer much help...but I totally agree with the above. I have learned that if someone says it's a walk in the park, I need to line up a backup vehicle and/or start early because I'm gonna be busting ass on it all day long (or all night if I don't start early)...and I'll most likely be breaking plenty more stuff along the way.
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Old 03-31-2010, 10:04 PM   #5
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Old 03-31-2010, 11:07 PM   #6
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I recall having the same question when I installed my RockHard bumper/carrier. I actually called them during the install and they picked up the phone and helped me out . . . might try calling Warn??? I didn't have to remove the gas tank, but I did need to loosen up the bolts and flex it down to get up in there. I also got a bit creative with some duct tape to keep the nuts attached to the wrench while I tried to manuever them in there. Good luck.
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Old 03-31-2010, 11:16 PM   #7
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When I installed my Warn rear I used about 6 extensions and a joint to put in those bolts.



I would not wheel with a tire on it till all the bolts are in personally. My carrier takes a lot of abuse with a 35 on it when I wheel.
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Old 04-01-2010, 08:00 AM   #8
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Hmmm...guess I'll give the gas tank another try tomorrow (without the GF standing over me this time) and see if I cant get at least a couple of those extra bolts in. I dont do too much wheeling and I have 33s, so in the short term Im not worried about it with just the five bolts.
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Old 04-01-2010, 05:42 PM   #9
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On my 98, I was able to get the two inner bolts on the passenger side with some really long extensions and a little cussing. I could not get the inner bolts on the drivers side though. I had to drop the gas tank just far enough to clear the skid mounting bolts (4 by the bumper, 3 on the axle side). Once clear of the bolts, I just pushed the tank/skid as far as I could to the passengers side and then I could access the bolts. It was still a bit of a pain, but manageable. With only dropping the tank that far, I did not have to disconnect anything EXCEPT that I did have to disconnect the filler hose from the tub. Just take out the screws on the filler bezel....easy day.

Here's a video that should help. They're working on an 05 but it's close enough to give you an idea of what you need to do to drop the tank:


Personally, I'd drop the bumper back off and get that broken bolt out before going any further, then go buy grade 8 hardware, then start over. But that's just me.
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Old 04-01-2010, 06:39 PM   #10
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Personally, I'd drop the bumper back off and get that broken bolt out before going any further, then go buy grade 8 hardware, then start over. But that's just me.
Im all ears......I'd love to get that broken bolt out, but after drilling and breaking 2 extractors (one of which is still stuck, further complicating the issue), Im out of ideas.

Appreciate the gas tank help, I only did the bumper side of the skid, so I guess I need to do the axle side as well to get that extra clearance and mobility.
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Old 04-01-2010, 07:20 PM   #11
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Storm27m has it totally right except for the fact that once you've unbolted everything that he said to unbolt, it's a simple matter to lower the tank/skid plate about 3 inches or so. If you can snag a helper to watch all the hoses on the drivers side it's a piece of cake. Just use a floor jack and a piece of 1/2" or 3/4" plywood and SLOWLY lower it down. As with anything else concerning working on your Jeep, do it right. Use all the bolts across the frame to avoid problems later.
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Old 04-01-2010, 07:22 PM   #12
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Quote:
Originally Posted by Catalog View Post
When I installed my Warn rear I used about 6 extensions and a joint to put in those bolts.



I would not wheel with a tire on it till all the bolts are in personally. My carrier takes a lot of abuse with a 35 on it when I wheel.
There is the problem right there, He probably didn't have a joint first.

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Old 04-01-2010, 08:28 PM   #13
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That video helps, thanks. Gives me a little extra confidence when it comes to 'dropping' a big tank full of gas.

I do want to do this right, half assing things bugs me, just not sure how to proceed with the broken bolt. Any other ideas? Like I said, already tried (and failed miserably) with some broken bolt removers.
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Old 04-01-2010, 09:33 PM   #14
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Can you grab the broken bolt from the backside with vise grips, or jam two nuts together and wrench it off that way?
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Old 04-01-2010, 10:59 PM   #15
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Originally Posted by 03 RUBI View Post
Storm27m has it totally right except for the fact that once you've unbolted everything that he said to unbolt, it's a simple matter to lower the tank/skid plate about 3 inches or so. If you can snag a helper to watch all the hoses on the drivers side it's a piece of cake. Just use a floor jack and a piece of 1/2" or 3/4" plywood and SLOWLY lower it down. As with anything else concerning working on your Jeep, do it right. Use all the bolts across the frame to avoid problems later.

I should have mentioned using the jack to support the tank....minor detail . I was also meaning to just lower the tank far enough to clear the bolts and then move it to the side, not completely drop the tank out. I did not disconnect any hoses (except filler) to do that. And doing it on 1/4 tank or less is much easier to deal with.

Not sure what else to recommend on the broken bolt, just meant that dropping the bumper to work on it might be easier.
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Old 04-02-2010, 08:42 AM   #16
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Can you grab the broken bolt from the backside with vise grips, or jam two nuts together and wrench it off that way?
Tried vise grips earlier this week.....managed to twist off more of the bolt . What do you mean by jam two nuts together?

As much as I hate to leave the broken bolt alone, if I can get the other 4 (inner) bolts in, I'll probably just let it be. I cant imagine that 1 bolt out of 10 being a huge deal.
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Old 04-02-2010, 02:08 PM   #17
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Well got all but the broken bolt in place. I guess Im settling for 9/10 bolts, as I tried once again at the stuck bolt to no avail.

Thanks all for the help, esp the gas tank video.
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Old 04-02-2010, 02:15 PM   #18
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Sometimes you can put 2 nuts on a bolt then jam them together in such a way that you can turn one or the other nut and it won't thread on or off the bolt. Hope that explains it.
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Old 04-07-2010, 08:16 AM   #19
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I have an older Warn bumper/tire carrier (probably installed around 2005). I will warn you to check for water accumulation in the main vertical tube of the tire carrier. It has a plastic cap on the top, supposedly to keep water out. It didn't on mine. In the winter the water froze and cracked the tube. If there isn't one, you might want to drill a hole in the bottom for water removal.

And from what I remember, it was a b*tch to get at some of the bolts. My brother did most of that... girly hands.

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