ARB 3450100 User Manual

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If you have any queries regarding the installation of this product please contact the distributor from whom it was purchased, or alternatively the ARB office in your state.

Head Office – ARB Corporation Ltd VIC: 42-44 Garden Street, Kilsyth, Victoria, 3137 Tel: [phone] Fax: [phone]

WA: [phone] NSW: [phone] ACT: [phone] SA: [phone] QLD: [phone] NT: [phone] TAS: [phone]

JEEP CHEROKEE GRAND WJ

PRODUCT NUMBER
3450100

WARNING

FOR VEHICLES EQUIPPED WITH SRS AIRBAG

WHEN INSTALLED IN ACCORDANCE WITH THESE INSTRUCTIONS, THE FRONT

PROTECTION BAR DOES NOT AFFECT OPERATION OF THE SRS AIRBAG.

TAKE NOTE OF 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 ATTEMPED.

• 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.

IMPORTANT

1 This winch bumper is suitable for Warn 8,000lb, 9,000lb & 9,500 low-mount

winches only.

WHEN FITTING THIS BULL BAR TO 1998 TO 2000 MODELS ONLY. IT IS RECOMMENDED
THAT THE VEHICLES HYDRAULIC COOLING SYSTEM BE UPGRADED TO 2001 TO 2003
SPECIFICATION.
INSTALLATION OF THIS BULL BAR TO THE EARLIER MODELS WITHOUT THE
COOLING SYSTEM UPGRADE MAY RESULT IN THE VEHICLE RUNNING HOTTER
THAN NORMAL.
CONSULT YOUR NEAREST JEEP DEALER FOR PARTS REQUIRED.

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FITTING KIT NUMBER 6171463

USE

PART No

QTY

DESCRIPTION

6151232

6

BOLT M10 x 30mm
4581040

6

WASHER FLAT M10
IMPACT ABSORBERS

4581048

6

WASHER SPRING M10
6151022

4

BOLT M8 x 25MM
4581044

4

WASHER FLAT M8
TO CHASSIS RAILS

4581046

4

WASHER SPRING M8
3756207

2

BRACKET CAPTIVE NUT
6151302

4

M10 CAGED NUT
3193666

2

PLATE CAPTIVE NUT
3756213L

1

1MPACT ABSORBER
3756213R

1

IMPACT ABSORBERS
BULL BAR TO

6151045

6

BOLT M10 x 25mm
IMPACT ABSORBERS

4581048

6

WASHER SPRING M10
4581040

6

WASHER FLAT M10
6151026

2

NUT M10
TO BOLT BUFFERS

6151128

8

NUT FLANGE M6
TO BULL BAR
6151021

2

BOLT M8 x 20mm
CONTROL BOX BRACKET

4581044

2

WASHER FLAT M8
3756209

1

CONTROL BOX BRACKET
6151132

2

NUT FLANGE M8
NUMBER PLATE BRACKET

6151017

4

BOLT M6 x 16mm
6151046

4

WASHER FLAT M6
6151128

4

NUT FLANGE M6
3751451

1

NUMBER PLATE BRACKET
BUFFERS AND INDICATORS

3500170

1

BUFFERS KIT
3500080

1

ARB INDICATORS
8-9000lb WINCH TO PAN

4581040

4

WASHER FLAT 3/8"x 1"
180302

6

CABLE TIES
6191001

1

EXTRUSION RUBBER
WINCH PAN COVER

6521036

1

PANEL WINCH COVER
6151256

2

SCREW BUTTON HEAD M6 x 16mm
6151128

2

NUT FLANGE M6
6151017

4

BOLT M6 x 16mm
PLASTIC INNER GUARDS

6151046

4

WASHER FLAT M6
6151128

4

NUT FLANGE M6
6151143

6

SCREWS SELF DRILL

AIR DEFLECTOR

3314452
6151017
6151128
4581072

1
3
3
3

AIR DEFLECTOR
BOLT M6 X 16mm
NUT M6 - FLANGE
WASHER M6 - FLAT

TOOLS REQUIRED

1 BASIC TOOL KIT, DRILL , ½" DRILL BIT. ¾" LONG REACH SOCKET (IF DRIVING LIGHTS
ARE TO BE FITTED).

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ASSEMBLY SEQUENCE FOR BULL BAR INSTALLATION.

1. Remove bumper bar and tow bracket from the
vehicle.

2. Cherokee Grand Limited has grille and bumper as
one piece, where Laredo has a chrome grille and
separate bumper bar.

3. If your vehicle is the Limited, your choice is to
either, separate grille from bumper bar by cutting
with a keyhole saw, or purchasing a Laredo
grille, part no. 55155921AA.

4. Photos supplied for cutting grille apart (refer page

6).

5. Once front of vehicle is stripped, spray paint satin
black using a pressure pak can. This is done to
hide vehicle colour that shows when bar is fitted
to vehicle.

6. Using a hammer, flatten lip over under front
crossmember on both sides of vehicle so impact
absorbers can be mounted flush against chassis of
vehicle.

7. Remove three bolts securing air deflector and
place aside. Remove two forward most bolts
securing bash plate to body.

8. Position impact absorber over aperture of front
crossmember and temporarily clamp to vehicle
using vice grips.

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9. Preassemble captive nut bracket and caged nuts
(see diagram), then insert captive assembly
through front of impact absorber into vehicle
crossmember aperture and align with holes in
bottom of chassis.

10. From underneath vehicle, fasten to chassis using
2 x M10 x 30mm bolts with flat and spring
washers and using existing bash plate bolt and
captive nut.

11. Drill 8mm holes through crossmember return
using impact absorber holes as template.

(WARNING: BEWARE OF AIRCONDITIONING
LINES AND WIRING LOOMS WHEN DRILLING.)

APERTURE
BEHIND
IMPACT
ABSORBER

CAPTIVE
NUT

Fit 8mm captive nut plate behind
crossmember return and align with 8mm
drilled holes.

Using M8 x 25mm bolts, flat and spring
washers, fasten through impact absorber to
8mm captive nut plate.
When all bolts are fitted, tighten firmly.

CAGE NUT

BRACKET

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12. If fitting the XP 9.5 winch, remove the cover
from the control box.

For any other winch, go to step 19.

13. Remove the two cap screws, nuts and spacer
washers that hold the four solenoids in place.

14. Remove the four solenoids from the base of the
control box using the copper bus bar as an aid
and hold to one side.

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Before

15. Remove the two bolts in the base of the control
box and reposition them into the more
centralised holes

After

16. Place the 4 solenoids over the 2 metal stands that
are facing upwards. Make sure they line up with
the holes in the base.

17. Replace the 2 cap screws, washers and nuts
removed in step 13 above into original holes.

18. Replace the black cover and refit the three cover
screws (DO NOT OVER TIGHTEN)

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(If using bar as a winch bar, follow as per
instructions below.)

19. Fit control box bracket to bar using 8mm
hardware.

20. Fit indicators into bar.

21. Fit number plate bracket to bar upward, or
downward for non winch bar, using 6mm
hardware.

22. Photo on left is number plate bracket in upward
position.

23. To place the clutch handle in the correct position,
the winch gearbox must be rotated 72 degrees (2
hole spacings) in an anti-clockwise direction
when viewed from gearbox end. Place the winch
on its end and remove all gearbox bolts. Gently
raise the gearbox just enough to rotate it. When
the correct position is located, refit all bolts and
tighten.

NOTE: Take care not to lift the assembly more

than a couple of millimeters while rotating to
correct position to avoid unmeshing the gears.

24. To fit roller fairlead to bull bar, you will need to

drill 2 x12mm holes into roller fairlead as per
diagram.

25.Once winch is rotated, position winch on bench

face up.

26. Lower bull bar on top of winch and align holes.

27. Place roller fairlead in bar cutout over lower
holes and fasten using 3/8" Warn hardware and 4
3/8" flat washers supplied in bolt kit.

28. To tighten bolts that hold roller fairlead to bar,
remove vertical rollers using circlip pliers.

29. When all is positioned, tighten all bolts firmly
and replace vertical rollers.

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30. Fit control box to control box bracket and tighten
firmly.

31. Pull wires through viewer cutout under control
box and wire up as per Warn instruction manual.

32. Tie back cables clear of all moving parts with
cable ties supplied.

33. Place ground earth lead under bolt of winch
tension bar.

34. Fit buffers to bar using 6mm hardware.

35. Lift bar into position between impact absorbers

and bolt up using M10 x 25mm bolts, spring and flat
washers. Finger tighten only. (Bolts fit from inside of
bar.)
36 .Adjust bar so that there is a 15mm gap around the
periphery of the vehicle and securely tighten all
remaining bolts throughout.

37. Next step is to lock pin the bar so there is no
movement by drilling a 10mm hole on both sides
of vehicle, and fasten with 10mm x 25mm bolts
plus 10mm hardware.

38.Wire main power leads to battery as per Warn

instructions and cable tie leads securely from all
moving parts with cable ties supplied.

39. Fit number plate to bar using 6mm hardware.

40. Pull winch cable through roller fairlead, and fit

tow hook.

41. Connect the indicator looms to the existing

indicator loom with the Scotchlocks supplied. Test to
ensure the indicators function correctly.

42. Drill out plastic inner guard panel with 6mm drill

bit using holes in bar return as template.

43. Secure with 6mm hardware.

Photo above shows cable ties holding leads in place.

Photo is from RHS of vehicle.

Photo is from LHS of vehicle.

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44. Notch out plastic inner guard panel level with

bottom of bar return, fold upward against bottom of
vehicle crossmember and secure using self tapping
screws.

45. If bar is to be a non winch bar, bolt cover panel to
bar using 6mm hardware.

46. The air deflector is mounted beneath the bull bar
using three of the existing bash plate bolts and three

M6 bolts and hardware supplied in kit.

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Carefully cut along joining line with a keyhole saw.