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WARN
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Contains Hardware And Wiring Required To Mount Control Box Remotely From Winch
Warn manufactures products and accessories for Automotive, Powersports, Industrial and commercial users. From self recovery winches and mounting systems to wheel end and driveline disconnects, Warn customers have chosen Warn products for their durability,
WARN Industries has built off-road recovery equipment since 1948, beginning with locking wheel hubs and expanding into the electric winch that made the brand a standard. The lineup covers truck, Jeep and SUV winches, powersports winches, industrial and hydraulic hoists, bumpers, mounting systems and rigging gear, manufactured in Clackamas, Oregon.
Arthur and Sadie Warn founded WARN Industries in 1948 with an idea for converting surplus World War II Jeeps into practical road vehicles. Arthur's locking wheel hub was the product that did it, and it went on to reshape the four-wheel-drive market. By 1954 WARN hubs were offered as factory optional equipment by major domestic automakers, and over the following decades the company supplied hubs as original equipment to Chrysler, Ford, GM, Kia, Nissan and others.
The defining moment came in 1959 with the electric winch. Before it, a vehicle-mounted winch ran off a power take-off and needed the engine turning to work. An electric winch could pull even with the vehicle stalled on a hill, which changed what recovery meant for four-wheelers, racers and ranchers. The M8274 arrived in 1974 and remains in the line. Today's truck, Jeep and SUV winches include the VR EVO, ZEON and ZEON Platinum families.
As the ATV market grew through the 1980s, WARN introduced the first purpose-built powersports winch and created a category. The current ATV and UTV winch range includes the VRX and AXON lines, the latter using a combined motor and contactor unit that cuts installation time substantially. Vehicle-specific winch mounts, bumpers and plow systems complete the fitment.
On the work side, WARN builds electric and hydraulic industrial winches and hoists for towing, utility, military and severe-duty applications, from the compact Drill Winch through 30,000 pound Series XL units and the modular Series G2. Recovery is supported by a full rigging range of straps, shackles, snatch blocks and dampers.
The company operates 180,000 square feet of manufacturing, engineering and office space in Clackamas, Oregon, employs close to 400 people, holds more than 100 patents and produces over 600 products under ISO 9001, ISO 14001 and IATF 16949 certified systems.
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Call 888-634-9494The ZEON® XD Control Pack Relocation Kit (part number 111708A0) is a relocation system for Warn Industries ZEON XD and ZEON Platinum winch control packs. It allows you to relocate the control pack away from its factory position. The kit includes mounting hardware, fasteners with specified torque values, and provisions for optional remote-controlled clutch harness extension for ZEON Platinum models.
The kit is compatible with ZEON XD and ZEON Platinum winch systems. The manual shows separate fastener specifications for ZEON XD Configuration and ZEON Configuration, indicating both versions are supported.
The kit includes the following fasteners: T45 head M8×1.25×25mm bolts (torque 15–17 Nm / 133–150 in-lb); T25 Plastite 6mm×25mm screws (torque 3–5 Nm / 27–44 in-lb); 13mm hex M8×1.25×14mm bolts (torque 10.6–13 Nm / 94–115 in-lb); 13mm hex M8×1.25×35mm bolts (torque 10.6–13 Nm / 94–115 in-lb); 8mm hex M5×0.8×16mm bolts (torque 4–5 Nm / 35–44 in-lb); 13mm hex M8×1.25 bolts (torque 8–9.5 Nm / 71–84 in-lb); 8mm hex M5×16mm bolts (torque 4–5 Nm / 35–44 in-lb); 10mm hex M6×16mm bolts (torque 4–5 Nm / 35–44 in-lb); T20 Torx M4×16mm screws (torque until seated); 13mm hex M8×35mm bolts (torque 10.6–13 Nm / 94–115 in-lb); 5/16"-18×1" bolts (torque 10.6–13 Nm / 94–115 in-lb); 5/16"-18 lock nuts (torque 10.6–13 Nm / 94–115 in-lb); M6 lock washers; and 5/16" washers.
The manual specifies fastener head types but does not provide a complete list of required tools. Based on the fasteners included, you will need: T45 and T25 Torx drivers, 13mm, 10mm, and 8mm hex sockets or wrenches, and a torque wrench capable of measuring in both Newton-metres and inch-pounds. Crimp connectors and a crimping tool are required for the optional remote-controlled clutch harness extension.
Remove all jewelry and wear eye protection. Never route electrical cables across sharp edges, near parts that get hot, or through moving parts. Never lean over the battery while making connections. Never route electrical cables over battery terminals or short battery terminals with metal objects. Always verify the area is clear of fuel lines, fuel tank, brake lines, and electrical wires before drilling. Always place supplied terminal boots on wires and terminals as directed. Never mount the contactor with electrical terminals touching metal objects. Observe precautions for handling electrostatic sensitive devices. Always consult the vehicle operator's manual for proper wiring details.
The torque specification for T45 head M8×1.25×25mm bolts is 15–17 Nm (133–150 in-lb).
The torque specification for T25 Plastite 6mm×25mm screws is 3–5 Nm (27–44 in-lb).
The torque specification for 13mm hex M8×1.25×14mm bolts is 10.6–13 Nm (94–115 in-lb).
The torque specification for 13mm hex M8×1.25×35mm bolts is 10.6–13 Nm (94–115 in-lb).
The torque specification for 8mm hex M5×0.8×16mm bolts is 4–5 Nm (35–44 in-lb).
The torque specification for 13mm hex M8×1.25 bolts is 8–9.5 Nm (71–84 in-lb).
The torque specification for 8mm hex M5×16mm bolts is 4–5 Nm (35–44 in-lb).
The torque specification for 10mm hex M6×16mm bolts is 4–5 Nm (35–44 in-lb).
The torque specification for T20 Torx M4×16mm screws is until seated (no specific torque value given).
The torque specification for 13mm hex M8×35mm bolts is 10.6–13 Nm (94–115 in-lb).
The torque specification for 5/16"-18×1" bolts is 10.6–13 Nm (94–115 in-lb).
The torque specification for 5/16"-18 lock nuts is 10.6–13 Nm (94–115 in-lb).
No. The remote-controlled clutch harness extension is optional for ZEON Platinum models only. If you need this extension, it must be cut and spliced with crimp connectors according to the installation instructions.
Yes, the kit is compatible with both ZEON XD and ZEON Platinum systems. The manual includes separate fastener specifications for each configuration.
You need a torque wrench capable of measuring from 3–5 Nm (27–44 in-lb) at the low end to 15–17 Nm (133–150 in-lb) at the high end, with the ability to read both Newton-metres and inch-pounds.
The manual does not explicitly state whether battery disconnection is required. However, it emphasizes never leaning over the battery during connections, never routing cables over battery terminals, and never shorting battery terminals. Consult your vehicle operator's manual for proper electrical disconnection procedures before beginning installation.
The remote-controlled clutch harness extension is optional and available only for ZEON Platinum models. It requires cutting, splicing, and crimping connectors if used.
Always verify the area is clear of fuel lines, fuel tank, brake lines, and electrical wires before drilling. Consult your vehicle operator's manual for the location of these components.
Torque specifications range from 3–5 Nm (27–44 in-lb) for T25 Plastite screws to 15–17 Nm (133–150 in-lb) for T45 head M8×1.25×25mm bolts. Most M8 bolts torque to 8–13 Nm (71–115 in-lb) depending on length and type. Always use a calibrated torque wrench and refer to the specific fastener diagram for each installation step.
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