Archive for the ‘ H3 Winch Mount ’ Category

Hummer H3 Winch Mount

DOI H3 winch mount bumper

The Defelice Offroad Innovations Hummer H3 winch mount is a one-piece bolt-on unit (no welding required). The H3 winch mount is laser cut and fabricated from 3/16-inch thick plate steel and provides you with a factory fit and look. This part is powder coated for durability and also retains the factory approach angle. The H3 winch mount comes pre-drilled with a standard 10.0 x 4.5 inch bolt pattern to install the Warn or T-Max winch of your choice (winch must have a remote mountable solenoid box such as Warn’s M8000, M9000, XD9000, etc…or the T-Max EW9000). The DeFelice Offroad Innovations Hummer H3 winch mount kit comes complete with the mount, longer wire leads, and Grade 8 hardware.

If  you are a retailers or distributor and are interested in carrying the DOI H3 Winch Mount please contact us.

Purchase the DOI H3 Winch Mount |  Four Wheeler Magazine Project Trailhugger H3 Install

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H3 Winch Mount Photos

Hummer H3 Winch Mount Installation Instrcutions

  1. Disconnect negative battery terminal.
  2. Remove the lower grill and bumper assembly.
    1. Use a small flat head screw driver remove the plastic pull rivets from inside the front of the wheel well. One on each side.
    2. Remove two 13mm hex head bolts on each side (four total) of the inner wheel well that attach the steel bumper to the lower plastic grill. Access the bolts from behind the wheel well plastic cover.
    3. Remove the four fasteners that attach the skid plate. Remove the skid plate.
    4. Disconnect driving lights in lower grill from the electrical harness.
    5. Remove the horizontal bolts and spring washers that retain the D-rings.
    6. Remove one bolt (two total) from each D-ring mounting plate. Loosen the remaining bolts.
    7. Support the bumper assembly with a sufficient jack or strong friend without beer in hand.
    8. Remove the remaining two bolts that attach the D-ring mounts.
    9. Carefully remove the bumper, lower grill, and if equipped brush guard assembly from the vehicle.
  3. Remove the lower grill from the steel bumper.
    1. Remove the five 10mm hex head bolts that attach the two pieces together.
    2. Remove the bolt retainer clips from the steel bumper.
    3. Do not discard the bolts or the retainer clips.
  4. Remove upper grill as follows:
    1. Make sure to mark locations of fasteners and shims if necessary. Some fasteners may not have shims.
    2. Remove the four fasteners on top.
    3. Remove the two fasteners on the bottom (access thru left and right slots of grill).
    4. Firmly grasp one side of grill around the turn signal. Pull on grill until slip-clips release. Pull grill only far enough to release slip-clips.
    5. Repeat step 4.d. for other side of grill. Pull grill only far enough to release slip-clips.
    6. Remove the grill from the vehicle.
  5. Install the winch solenoid box and longer leads..
    1. Remove the three screws on the solenoid box cover.
    2. Remove the green Warn lead and replace with the green DOI lead.
    3. Remove the yellow Warn lead and replace with the yellow DOI lead.
    4. Remove the blue Warn lead and replace with the blue DOI lead.
    5. Re-install the solenoid box cover and screws.
    6. Mark holes to be drilled to mount solenoid box to vehicle. Mark the top hole 1-1/4 inch down from the center of the lower hood latch bolt. Measure the distance from the top bolt on the solenoid box to get the dimension for the location of the lower bolt hole. Use a ¼ inch (0.250 in.) diameter drill bit to make a hole in the hood latch support.
    7. Put the solenoid box upside down on the hood latch support. Install and tighten the washers and nuts.
    8. Route the Red lead to the battery.
    9. Install the top grill and check for winch control plug clearance. If necessary adjust location of solenoid box.
    10. Cut a 1-1/2 inch diameter hole in the lower passenger side of the air-dam.
    11. Route the DOI winch cables thru the hole.
  6. Clock the free-spool assembly on the winch.
    1. Stand the winch vertically with the motor facing down and the free-spool handle facing you.
    2. Put a scribe line (or mark) from the bolt head to the left of the free-spool handle down to the base of the lower ring.
    3. Use the bolt to the left of the free-spool handle as bolt number one. Count over five bolts and put a scribe mark in-line with the number five bolt on the winch mounting assembly. Your mark should not be on the free-spool assembly or the lower ring.
    4. Remove 8 of the 10, 5/32 Allen screws that attach the free-spool assembly to the winch. Loosen the two remaining screws completely but do not remove.
    5. Lift the free-spool assembly and lower ring approximately ¼ inch from the winch assembly.
    6. Rotate the free-spool assembly counterclockwise until the number one bolt mark aligns with the number five bolt mark. The cable spool should turn with the free-spool assembly.
    7. The free-spool assembly should fit flush at both gasket locations. It may be necessary to tap that top of the free-spool assembly with your hand (not a hammer). DO NOT PULL TOGETHER WITH BOLTS!
    8. Install all ten of the 5/32 bolts finger tight.
    9. Tighten the ten bolts in an alternating pattern. Tighten one bolt; the next bolt to tighten should be 180 degrees from that bolt, repeat until all ten bolts are tight.
  7. Assemble the winch, DOI winch mount, and lower grill as follows:
    1. Install the roller fairlead with the two 3/8-16 flat head screws. Make sure the screw heads are on the inside of the winch mount and the washer, lock washer, and nut are on the outside of the roller fairlead. Use bolt holes adjacent to winch cable access hole. Tighten the bolts.
    2. Use a ½ inch (0.500 in.) drill bit to make two holes in the roller fairlead. Use the lower two holes in the winch mount as a template.
    3. Replace the Warn ground cable with the DOI ground cable.
    4. Place the square nuts with the flat side towards the front in the winch assembly mounting holes. Put masking tape over the holes to hold the square nuts in place.
    5. Cut the winch cable loose and feed thru the DOI winch mount and roller fairlead.
    6. Place the winch inside the DOI winch mount. Make sure that the free-spool lever aligns with the cut-out in the winch mount.
    7. Install the four bolts that attach the winch to the winch mount. Tighten to the specifications provided by Warn.
    8. Put the five bolt retainer clips on the top of the DOI winch mount.
    9. Bolt the lower grill to the top of the DOI winch mount.
  8. Install the upper and lower grill and DOI winch mount assembly.
    1. Use a jack to raise the winch mount assembly close to the vehicle but with enough space to route and attach the winch leads.
    2. Set the winch mount assembly on jack stands or equivalent. Make sure the winch mount assembly is secure on the jack stands before installing the leads.
    3. Route negative (black) lead from winch motor thru the 1-1/2 inch hole in the air-dam and to the battery.
    4. Attach color coated DOI leads to color coded studs on the winch motor and tighten. Make sure to match up the colors correctly.
    5. Install the upper grill. Make sure all the slip-clips are attached.
    6. Install the lower grill and DOI winch mount assembly without brush guard as follow:
      1. Use the factory D-ring mount and bolts to attach the assembly to the vehicle.
      2. Tighten all the bolts.
    7. Install the lower grill and DOI winch mount assembly with brush guard as follow:
      1. Put the plastic shim under the brush guard.
      2. Put the brush guard then the D-ring mounts.
      3. Use the factory D-ring mount and bolts to attach the assembly to the vehicle.
    8. Assembly of the rest of the factory hardware is the reverse order of the disassembly.
  9. Connect the winch cables to the battery terminals.
  10. Make sure all hardware is tight and all connections are secure.