CT Style winch tray install

robertf

Well-known member
Jan 22, 2006
4,510
197
-
Thought some of you might want to see what is involved in installing one of these on a NAS D1.

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REMOVE

Front bumper
disconnect headlight washer hose from tee fitting
undo side marker light bulb connection
remove 10mm nut holding side bumper cap to fender
remove 4x bumper to frame bolts
remove bumper, set aside


Auxiliary transmission cooler

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place pan under each frame rail
loosen nut from cooling line on each side of cooler
remove cooler line, discard o-ring
remove 4x fasteners using 10mm wrenches, set cooler aside
remove upper transmission line from radiator, set aside

hood latch and support bars
remove fasteners and spacers from lower hood support bars using 10mm wrenches
remove 3x fasteners from hood latch using 10mm and 8mm wrench
disconnect spring from latch, set aside

air dam between bumper and radiator (usually gone by now, but remove bolts if they are still there)
remove fasteners using 10mm wrenches


refrigerant dryer/filter bracket

remove 3x screws using 10mm socket
slide filter bracket down from dryer




Modifications:

refrigerant dryer/filter bracket

cut bracing on lower tab of bracket, rebend tab to position flange approx .15" further away
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rebend upper tab to position flange .15" further away
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paint, reinstall
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horns
remove horns
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reinstall on opposite side
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hood latch and support bars
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drill new hole on left side of grill to move support bar back as far as possible without bending against the aux fan
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apply paint to bare metal
reinstall hood latch support bars and spacers, using new hole on left side, original hole on right side
reinstall hood latch and spring
 

robertf

Well-known member
Jan 22, 2006
4,510
197
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auxiliary transmission cooler

remove 2x fasteners holding bracket to right side of transmission cooler using 10mm wrench
discard bracket
install new bracket on right side
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install spacer bracket on left side using fasteners from air dam
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hold cooler up in new location, mark new holes
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drill new holes
apply paint to bare metal
reinstall cooler using original 4x fasteners
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cut socket off of upper radiator trans cooler line, do not damage 1/2" tube
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remove socket and hose from tube
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cut remaining line as shown in photos
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robertf

Well-known member
Jan 22, 2006
4,510
197
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install 1/2" to -8 AN male fittings as shown
make up hoses using 45 and 90 for the right side, and 0 and 90 for the left.
Install as shown

Winch tray install:

install winch to tray
use lifting table to raise tray in to place
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place bumper bolts through winch tray, do not tighten
install rear frame rail supports, tighten
bumper bolts should be easily removed at this point
cut front bumper along outside edge of crash can
apply paint to bare metal
place bumper ends on frame
install bolts, tighten
wire winch
done
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Dave P

Well-known member
May 4, 2018
66
11
Central MA
That’s pretty cool, nice work. I bought one from Portugal a few years ago and it installed pretty much the same way. I like the Dayton Superwinch- good find!C620118A-1BA9-4B23-936D-C2F246D92E49.jpegC8943054-4B3A-45CD-9C4C-DD9F54240CC7.jpeg
 

robertf

Well-known member
Jan 22, 2006
4,510
197
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Nice! Id seen those for sale a while back but already had one drawn up so didnt look into it too much
 

robertf

Well-known member
Jan 22, 2006
4,510
197
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Thanks, took lots of practice and even more screw ups to figure it out

I'm in Texas.


I started on the wiring this afternoon, but the cold front put a halt to that.
 

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robertf

Well-known member
Jan 22, 2006
4,510
197
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And the most important piece, the winch light
 

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Dave P

Well-known member
May 4, 2018
66
11
Central MA
Ok, so you really have to post more on the brush bar. I kind of gave up on finding one so when a non-winch ARB came up nearby, I bought it and fitted it to work with the CT style winch tray. Crazy but it all fits together even with a Safety Devices steering guard.
 

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