ARB 3438320 User Manual

Part Number:
Product

3438320 F/Kit 6172684
Deluxe Combination Winch and Non Winch Bull Bar

Description:
Suited to

Nissan D40 Frontier 09 ON USA Only

vehicle/s:

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:

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

♦ Do not use this product for any vehicle make or model, other than those specified by ARB.
♦ Do not remove labels from this bull bar.
♦ This product or its fixing must not be modified in any way.
♦ The installation of this product may require the use of specialized tools and/or techniques
♦ It is recommended that this product is only installed by trained personnel
♦ 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

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

components

♦ Work safely at all times

♦ Unless otherwise instructed, tighten fasteners to specified torque

ARB 4x4 ACCESSORIES

Corporate Head Office

42-44 Garden St Tel: [phone]
Kilsyth, Victoria Fax: [phone]
AUSTRALIA 3137

Australian enquiries [e-mail]
North & South American enquiries [e-mail]
Other international enquiries [e-mail]

www.arb.com.au

Last Rev Date: 17/11/2009 Page 1 of 18 Fitting instructions# 3787059

Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd

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 3 & 10mm DRILL BITS

SHARP KNIFE PHILLIPS AND FLAT SCREW DRIVER SET

FELT TIP PEN HACKSAW BLADE OR SMALL HAND SAW

FINE FILE OR SAND PAPER ELECTRIC JIG SAW

METRIC TAPE MEASURE ROLLS OF 25 mm & 50 mm WIDE MASKING TAPE

HAVE AVAILABLE THESE SAFETY ITEMS WHEN FITTING PRODUCT:

Protective eyewear

NOTE: ‘WARNING’ notes in the fitting procedure relate to OHS situations, where to avoid a
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.

Hearing protection

FASTENER TORQUE SETTINGS:

SIZE Torque Nm Torque lbft

M6 9Nm 7lbft

M8 22Nm 16lbft
M10 44Nm 32lbft
M12 77Nm 57lbft

NOTE:

♦ OPTIONAL FOG LAMPS TO SUIT THIS PRODUCT ARE P#6821201.

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

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

Last Rev Date: 17/11/2009 Page 2 of 18 Fitting instructions# 3787059

Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd

IF LOOM AND SWITCH

APPLICATION. PART NO. QTY DESCRIPTION

MOUNT BRACKET (IMPACT

ABSORBER) TO CHASSIS

BULL BAR TO MOUNT BRACKETS

BUFFERS TO BULL BAR

PARTS LISTING

3757756R&L

6151095
4581049
4581050
6151360

4581007
4581050
6151428

3162470R&L

6151128

1 PR

8
8
8
6

6
6
6

1 PR

12

BRACKET ASSY IMP ABS RH & LH
BOLT M12 X 1.25 X 35 (FINE PITCH)
WASHER FLAT M12
WASHER SPRING M12
BOLT M12 X 1.75 X 35 (COARSE PITCH)

WASHER FLAT M12 X 37 X 4
WASHER SPRING M12
NUT FLANGED M12
BUFFER SLOTTED RH & LH
NUT FLANGED M6

LICENCE PLATE TO BULL BAR

LIGHT INSERT AND INDICATORS

WINCH TO BULL BAR

WINCH COVER

(NOT FITTING WINCH)

STONE TRAY BRACE TO

IMPACT ABSORBERS

STONE TRAY TO BULL BAR

PINNING BOLT HARDWARE

MISCELLANEOUS

6151384
6821189

3163015

6821151R&L

6821152

180701

3756499

EG50
6151074
6151073
4581040
4581048
6151022
6151132
4581044

180302

6522720
6151256
6151128
6191006
4681302
6151022
4581044
4581046
6151132
6151300

6522721
6151300
6151213
4581082
4581287
6151357
6151321

180302
6191020
3787023

2
2

1

1 PR

1
6
1
2
2
2
4
4
2
2
2
6
1

2
2
1
1
2
2
2
2
2

1
4
6
6
6
4
4
6
2
1

SCREW PAN HD
GROMMET RND HD

COMBINATION LIGHT SURROUND KIT
INDICATOR/CLEARANCE LAMP RH/ LH
LOOM INDICATORS
SCOTCH LOKS
CONTROL BOX MOUNT
RUBBER GROMMET
BOLT 3/8” x 1 ¾” HEX HEAD
BOLT 3/8” x 1 ½” HEX HEAD
WASHER FLAT M10
WASHER SPRING M10
BOLT M8 x 25mm
NUT FLANGE M8
WASHER FLAT M8
CABLE TIES
PANEL WINCH COVER

SCREW M6 X 16MM BUTTON HEAD S/S
NUT FLANGE M6
EXTRUSION WINCH COVER
BRACE STONE TRAY
BOLT M8 x 25 mm LONG
WASHER FLAT M8
WASHER SPRING M8
NUT FLANGE M8
CAGE NUT M6 ( LONG LEG )

STONE TRAY
CAGE NUT M6 ( LONG LEG )
BOLT M6 x 20 BZ
WASHER FLAT M6 x 20 BZ
WASHER SPRING M6 BZ
BOLT SEMS M10 x 25 mm LONG
NUT FLANGE M10
CABLE TIES
PINCH WELD 400mm NARROW LONG
TEMPLATE BUMPER CUT

Last Rev Date: 17/11/2009 Page 3 of 18 Fitting instructions# 3787059

Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd

PREPARATION TO VEHICLE

1. Remove licence plate from the vehicle and
set aside

.

2. Remove the three plastic scrivets securing
the bumper in the intake area behind the
licence plate location

3. Remove the bolts from the spoiler between
the lower bumper and sump guard

4. Remove the four lower bolts that attach the
lower bumper tabs to the vehicle (refer to
attached photo). There are also another two
self tapping screws in each side, located in a
recess in the lower bumper face – these need
to be removed.

5. Remove the two bolts and screw from the
fender opening area each side that attaches
the bumper bar to the plastic inner guard liner
as shown.

6. Remove the screws securing the fender liners
to bumper in the forward wheel arch areas

7. Remove the screws and speed nuts from the
bumper on each side in the wheel arch area
located vertically above wheel and tire.

Last Rev Date: 17/11/2009 Page 4 of 18 Fitting instructions# 3787059

Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd

PREPARATION TO VEHICLE

8. Remove the grille

9. Remove the bumper (disconnect fog lamps if
fitted)

10. With the bumper on a soft non abrasive
surface, undo the bolts securing the upper
and lower halves then split the bumper and
refit only the top section to the vehicle

Align with split
line and wheel
arch

11. Cut out the supplied paper template

12. Fit the cutting template as shown, aligning the
key reference points with the bumper then
tape in position

13. Mark the cutting line with a marking pen

14. Remove and reverse then fit the template to
the LHS, mark the cutting line once again.

Last Rev Date: 17/11/2009 Page 5 of 18 Fitting instructions# 3787059

Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd

PREPARATION TO VEHICLE

View in wheel arch
area after cutting

15. Remove the template then mask the area to
be cut with 50 mm masking tape to protect
the surrounding surfaces.

16. Cut from wheel arch area first on each side
with the electric jig saw, a second cut may be
necessary to fully cut the support structure
that sits behind the bumper bar.

17. Clean up the cut edges of the bumper bar
with a file or fine sand paper.

View after cutting

18. Starting at the wheel opening end pull the
outer bumper outward slightly and slip the
trim over the cut edge and work the trim
forward.

HINT: You can use a flat blade screwdriver to
prise the bumper away from the reinforcing
structure behind so the trim can be inserted

Last Rev Date: 17/11/2009 Page 6 of 18 Fitting instructions# 3787059

Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd