Rubi Driver

This week, I finally completed a Winch install. Doing so required relocation of the Vacuum Assist pump which is located inside the front bumper. A few kits have emerged to accomplish this goal, however many of them are quite complicated, and also expensive. For those looking to locate a winch inside the bumper (hidden install), these kits may be necessary. For an on-bumper install -- like the one I did using the Rugged Ridge XHD system -- such kits are not necessary. Here's a how-to on the solution we worked up.

First, the vacuum assist in it's factory position:



As you can see in this photo, it is mounted on a bracket welded to the inside of the frame member. It is attached to the bracket by threaded studs which are contact welded upwards through the bracket. This leaves the vacuum assist too high for most aftermarket bumper applications. To address the height issue, we simply moved the part down, using the same bracket with some simple modifications.

First we cut off the threaded posts:



We then drilled out the remainder to leave a hole for a new bolt:



Finally, we put a 3" bolt down through the new hole, added a 3/4" stand-off (piece of small pipe!), and put the part back on. To retard any corrosion problems, we coated the bolt with gasket sealer, as well as painted the cut and drilled area with primer before install. Finally, to ensure a firm, rattle-free mount, we reversed the factory grommets and added a washer. Finally, we made sure the set up left the part at least 1/4" above the bottom frame cross member.

Here's the finished result:



The net cost of this mod was about $1 in bolts, nuts and sealant and it took much less than an hour to complete. One added benefit of this change is now the part and it's connections can be reached and removed if necessary without removing the bumper. (If you have the ability, it's best to tack weld the top of the new bolt to the bracket so that it won't spin if you have to remove and reinstall the part.)

I've not seen this solution proposed elsewhere, so wanted to share my results. I hope this post helps someone else facing the same situation.

Rubi Driver

So, am I really the only guy to have faced this issue?

powrsurg

Im going to be facing this issue soon as I just ordered new bumpers. WInch coming soon after. The bumper comes with a relocation kit. It was only $20 more I think. SOmething tells me more people will stat looking at this tread as they start to swap out their bumpers.

PS - Youre solution is brilliantly simple. Im just not sure it wil work for all bumpers.

Little R6

Thanks for the post with pictures, I like to see someone "make" something for their project instead of always spending money because it's the easy way out!

offcamber

I just cut it off and plugged the hoses. Problem solved.

powrsurg

Too funny. Has that caused any lights to show up on the Dash?

Rubi Driver

Well, that certainly takes less time.