ARB 3421520 User Manual

Last Rev Date: 14/10/2010

Page 1 of 22

Fitting instructions# 3787836

Part Number:

3421520 F/Kits 6173065

Product Description:

Deluxe Combination Winch Bull Bars

Suited to vehicle/s:

TOYOTA 4 RUNNER 2010 ON

WARNING

REGARDING VEHICLES EQUIPPED WITH SRS AIRBAG;

When installed in accordance with these instructions, the front protection bar does not affect operation of the SRS airbag.

ALSO, NOTE THE FOLLOWING:

i This product must be installed exactly as per these instructions using only the hardware supplied.

i In the event of damage to any bull bar component, contact your nearest authorised ARB stockist.

Repairs or modifications to the impact absorption system must not be attempted.

i Do not use this product for any vehicle make or model, other than those specified by ARB.

i Do not remove labels from this bull bar.

i This product or its fixing must not be modified in any way.

i The installation of this product may require the use of specialized tools and/or techniques

i It is recommended that this product is only installed by trained personnel

i These instructions are correct as at the publication date. ARB Corporation Ltd. cannot be held

responsible for the impact of any changes subsequently made by the vehicle manufacturer

i During installation, it is the duty of the installer to check correct operation/clearances of all

components

i Work safely at all times

i Unless otherwise instructed, tighten fasteners to specified torque

ARB 4x4 ACCESSORIES

Corporate Head Office

42-44 Garden St Tel: +61 (3) 9761 6622 Kilsyth, Victoria Fax: +61 (3) 9761 6807 AUSTRALIA 3137

Australian enquiries sales@arb.com.au North & South American enquiries sales@arbusa.com Other international enquiries exports@arb.com.au

www.arb.com.au

Last Rev Date: 14/10/2010

Page 2 of 22

Fitting instructions# 3787836

GENERAL CARE AND MAINTENANCE

By choosing an ARB Bar, you have bought a product that is one of the most sought after 4WD products

in the world. Your bar is a properly engineered, reliable, quality accessory that represents excellent value. To keep your bar in original condition it is important to care and maintain it following these recommendations:

 Prior to exposure to the weather your bar should be treated to a Canuba based polish on all exposed

surfaces. It is recommended that this is performed on a six monthly basis or following exposure to salt, mud, sand or other contaminants.

 As part of any Pre Trip Preparation, or on an annual basis, it is recommended that a thorough visual

inspection of the bar is carried out, making sure that all bolts and other components are torqued to the correct specification. Also check that all wiring sheaths, connectors, and fittings are free of damage. Replace any components as necessary. This service can be performed by your local authorized ARB Stockist.

FITTING REQUIREMENTS

REQUIRED TOOLS FOR FITMENT OF PRODUCT:

METRIC SOCKET SET

METRIC RING AND OPEN ENDED SPANNER SET

ELECTRIC DRILL 13MM CAPACITY

3, 7, 8.5, 10, 13 &19mm DRILL BITS (19mm holesaw)

SHARP KNIFE

PHILLIPS AND FLAT BLAD SCREW DRIVER SETS

FELT TIP NON PERMANENT MARKER PEN

HACKSAW BLADE

FINE FILE OR SAND PAPER

ELECTRIC JIG SAW

METRIC TAPE MEASURE

ROLLS OF 25 mm & 50 mm WIDE MASKING TAPE

TOUCH UP PAINT ± BLACK FAST DRYING ENAMEL

SCISSORS

COLD CHIZEL

HAVE AVAILABLE THESE SAFETY ITEMS WHEN FITTING PRODUCT:

Protective eyewear

Hearing protection

127(µ:$51,1*¶QRWHVLQWKHILWWLQJSURFHGXUHUHODWHWR2+6VLWXDWLRQVZKHUHWRDYRLGD

potentially hazardous situation it is suggested that protective safety gear be worn or a safe work procedure be employed. If these notes and warnings are not heeded, injury may result.

FASTENER TORQUE SETTINGS:

SIZE

Torque Nm

Torque lbft

9Nm

7lbft

22Nm

16lbft

M10

44Nm

32lbft

M12

77Nm

57lbft

NOTE:

i OPTIONAL FOG LAMPS TO SUIT THIS PRODUCT ARE P#6821201. IF LOOM AND SWITCH REQUIRED

USE P#MD02 LOOM KIT, P#180209 SWITCH AND P#180215 SWITCH CAP FOR FOGS

i UP TO 900 SERIES ROUND OR 800 RECTANGULAR DRIVING OR FOG LAMPS SUIT THIS PRODUCT

Last Rev Date: 14/10/2010

Page 3 of 22

Fitting instructions# 3787836

PARTS LISTING

APPLICATION.

PART NO.

QTY

DESCRIPTION

MOUNT BRACKET (IMPACT

ABSORBER) TO CHASSIS

3758067R&L 3757995R&L

6151040 4581040 4581048 6151306 3194155 6151094 4581049 4581050 6151360 6151428 6151511 5811044 5811009

1 PR 1 PR

8 8 8 2 2 2

8 8 7 1 1 1

BRACKET ASSY IMP ABS RH & LH BRACE BOLT M10X1.25P(FINE)X30 WASHER FLAT M10 X 25 X 3THICK WASHER SPRING M10 NUT CAGE M12 X 1.75P PLATE EXTENSION CAGE NUT BOLT M12 X 1.25P(FINE) X 30 WASHER FLAT M12 X 25 X 3THICK WASHER SPRING M12 BOLT M12 X 1.75 X 35 (COARSE PITCH) NUT FLANGED M12 BOLT M12 X 1.75 X 100 SLEEVE ID 13 @ 50MM SLEEVE ID 13 @ 20MM

BULL BAR TO MOUNT BRACKETS

6151360 4581007 4581050 6151428 6151357 6151321

6 6 6 6 4 4

BOLT M12 X 1.75 X 35 (COARSE PITCH) WASHER FLAT M12 X 37 X 4 WASHER SPRING M12 NUT FLANGED M12 BOLT SEMS M10 x 30 LONG NUT FLANGE M10

BUFFERS TO BULL BAR

3162470R&L

6151128

1 PR

BUFFER SLOTTED RH & LH NUT FLANGED M6

LICENCE PLATE TO BULL BAR

6151384 6821189

2 2

SCREW PAN HD GROMMET RND HD

LIGHT INSERT AND INDICATORS

3163015

6821151R&L

6821152

180701

1 PR

2 6

COMBINATION LIGHT SURROUND KIT INDICATOR/CLEARANCE LAMP RH/ LH LOOM INDICATORS SCOTCH LOKS

WINCH TO BULL BAR

3756499

EG50 6151074 6151073 4581040 4581048 6151234 6151132 4581307

180302

1 2 2 2 4 4 2 2 2 6

CONTROL BOX MOUNT RUBBER GROMMET

%2/7´[ô´+(;+($' %2/7´[ò´+(;+($'

WASHER FLAT M10 WASHER SPRING M10 BOLT M8 x 25mm NUT FLANGE M8 WASHER FLAT M8 CABLE TIES

BRACE STRAPS

4681358 6151357 6151321

2 6 6

STRAP BRACE LOWER BOLT SEMS M10 x 30 LONG NUT FLANGE M10

STONE TRAY TO BULL BAR

6522802 6151300 6151213 4581082 4581287

1 4 6 6 6

STONE TRAY CAGE NUT M6 BOLT M6 x 20 BZ WASHER FLAT M6 x 20 BZ WASHER SPRING M6 BZ

WING UNDER PANELS TO BULL

BAR

6522801R&L

6151300 6151213 4581082 4581287 6151234 4581303 4581047 6151132

1 PR

14 14 14 14

2 2 2 2

PANEL WING UNDER SIDE CAGE NUT M6 BOLT M6 x 20 BZ WASHER FLAT M6 x 20 BZ WASHER SPRING M6 BZ BOLT M8 x 25 LONG BZ WASHER FLAT PANEL M8X 25X3mm BZ WASHER SPRING M8 BZ NUT FLANGE M8

Last Rev Date: 14/10/2010

Page 4 of 22

Fitting instructions# 3787836

MISCELLANEOUS

180302 6191020 3787837 6151234 4581307 4581047 6151132 6821231

2 1 2 2 2 2 1

CABLE TIES PINCH WELD NARROW 400mm LONG TEMPLATE BUMPER CUT BOLT M8 x 25 LONG BZ WASHER FLAT PANEL M8 BZ WASHER SPRING M8 BZ NUT FLANGE M8 CONDUIT ID10 @ 500mm

PREPARATION TO VEHICLE

1. Remove number plate

2. Using a non permanent marker, measure and

PDUNDSRLQWPP´GRZQIURPWKH

bumper and fender join both sides of vehicle

3. Mark a position for the cutting line at 90mm (3

ò´GRZQIURPEXPSHUWRJULOOHVXUURXQGMRLQ

inboard of headlamp as shown, repeat on other side of vehicle

Mark cutting line at 25mm down from join

Mark cutting line at 90mm down from join Join of bumper to grille surround

Wheel arch

Flare

Grill

Last Rev Date: 14/10/2010

Page 5 of 22

Fitting instructions# 3787836

PREPARATION TO VEHICLE

4. Mark a straight, horizontal line joining the marked cutting points on each end of the bumper

5. Using scissors accurately cut out the bumper cutting template along designated bumper cutting line as shown.

6. Carefully and accurately fit the template to the RHS of the bumper using the identified reference points aligning with the join of bumper, guard and the head lamp outer lower corner and tape in position. Make sure the

template sits as flat as possible on the bumper as any misalignment could affect the final cut profile accuracy on the vehicle.

7. Repeat for other side of vehicle

Mark cutting line

Headlamp, bumper and fender join

Mark cutting line on this edge, down to marked horizontal line

Last Rev Date: 14/10/2010

Page 6 of 22

Fitting instructions# 3787836

PREPARATION TO VEHICLE

8. Temporarily apply some masking tape joining the cutting line positions from each of the bumper outer sections. Apply the tape so the top edge is on the cutting line

9. Apply 50mm masking tape along the top side of the cutting line right across the bumper as shown.

NOTE: The bottom edge is on the cutting line

10. Once bumper cutting has been marked out, the bumper can be removed

11. Remove the plastic rivets securing the courtesy panel above the grille

Marked cutting line

Marked line from template

Last Rev Date: 14/10/2010

Page 7 of 22

Fitting instructions# 3787836

PREPARATION TO VEHICLE

12. Remove the plastic scrivets securing the top of the grille

13. Release the clip positions along the lower edge of the grille to the bumper then remove grille

14. Remove the plastic rivets securing the top of the bumper

15. Remove the screws securing the bumper to wheel arch area and across the lower section across the front so that there are no more fasteners securing the bumper

16. Remove the lower joining panel from the bumper to the sump guard

17. Work the inner guard liners away from the bumper and reaching in behind, undo the connections to the following if fitted:- fog lamps, parking sensors (connection is on LHS of vehicle), headlamp washers (use a cable tie to crimp off the hose to prevent washer bottle leaking).

+ 15 hidden pages

ARB 3421520 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual