Picked up a used Warn Rock Crawler front bumper and tried installing it today. It did not come with any hardware, just the brackets and bumper itself. I followed the instructions from warn. Since I did not have the spacer plates I used some washers between the frame and the brackets. It seems that the bumper is riding too close to the grill and I cannot get it to fit. I'm trying to use 1 1/2" long carriage bolts, should I be using longer? The only other option I could see to mounting it would be to cut the grill a little bit, but I feel it shouldn't be necessary. I'd really appreciate some help.

1994 4WD DLX 3VZE

Pictures would help.

Carriage Bolts ??

Well if it is to close to the grill move it out away from the grill.

Simple matter to make some spacers .

How much do you need to move 1/8" or 1/4" I doubt much more ??

Is this bumper made for your truck or a truck not even close??

My thoughts exactly. For a bumper, especially a heavy offroad bumper, you will want grade 8 hardware. I'm gonna assume you got these carriage bolts from your local hardware store. Regular hardware store carriage bolts are generally grade 5 or less. Grade 8 carriage bolts are out there, but are not generally used in automotive applications.

maybe since its used, the bumper has seen some sort of contact with something in the past which bent it slightly? Definitely want grade 8 hardware, always.

^This. When in doubt, go grade 8.

I'll try to get some pictures up if it ever stops snowing in NY when I have free time.
Here is the link for installation instructions from Warn [URL]http://static.summitracing.com/global/images/instructions/wrn-68466a0-pn68450.pdf
I did verify that I have the correct bumper through the part numbers.
And I definitely made sure that I got all Grade 8 hardware or Grade 10.9 in the case of the metric bolts.
I looked over the bumper a few times and it doesn't appear to have any damage or tool/machine marks from a repair. But I will check again, the thought didn't cross my mind as I was attempting the install.
I spoke to a representative from Warn today and was able to order the frame spacer places that I assume are causing me some issues. I'll update everyone when I get these in and can give it another shot.

This bumper has notches in the mounts for carriage bolts??

It should quit snowing about the second week in May

Wow, last time I logged in was 2/11/12, didn't think it was that long ago!

Pics would be a big help.
I've had that same bumper on my truck for about 5yrs and it is mounted perfectly level and even from side-to-side, I'm sure that I can help if I could see what looks different on your truck compared to mine.