ARB 3452020 User Manual

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Page 1

Part Number: Product

3452020 COMBAR DODGE RAM 2003-05

Description: Suited to

vehicle/s:

1500 2002-05 ADD BRACKET KIT# 3552010 2500/3500 2003-05 ADD BRACKET KIT# 3552020

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: +61 (3) 9761 6622 Kilsyth, Victoria Fax: +61 (3) 9761 6807 AUSTRALIA 3137

Australian enquiries [email protected] North & South American enquiries [email protected] Other international enquiries [email protected]

www.arb.com.au

Last Rev Date: 11-Sep-2006 Page 1 of 16 Fitting instructions# 3783239

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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 SPANNER and SOCKET TOOL SET Sikaflex© Black

PHILIPS and FLAT BLADE SCREWDRIVERS DIA 19mm HOLESAW

POWER DRILL DIA 13mm CHUCK CAPACITY DRILL BITS, DIA 7.0 (@100mm min), 10.0mm

STEEL RULE 300mm SCRIBER

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 4lbft

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

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PARTS LISTING

APPLICATION. PART NO. QTY DESCRIPTION

MOUNT BRACKETS TO VEHICLE

1500 MODEL ONLY

(BRACKET SET 3552010)

MOUNT BRACKETS TO VEHICLE

2500/3500 MODELS ONLY

(BRACKET SET 3552020)

WINCH

TOW HOOK RELOCATION

3756934L

3756934R

6151299 6151321 4581040 5811029

3756938L

3756938R

6151299 6151321 4581040

BRACKET BAR MOUNT LHS

BRACKET BAR MOUNT RHS

BOLT M10 X 100

NUT M10 FLANGED

WASHER M10 X 3mm

SLEEVE @ 70mm

BRACKET BAR MOUNT LHS

BRACKET BAR MOUNT RHS

BOLT M10 X 100

NUT M10 FLANGED

WASHER M10 X 3mm

180302 8 CABLE TIE

6151365 6151361 3756765 4581300 6151046

EYEBOLT M24 2.5T SWL

NUT M24 GR8 ZP

BRACKET NUT RETAINING

WASHER M24 EYEBOLT

WASHER M6 6151017 6151128

CONTROL BOX FITTMENT 4581291

6151321 6151364 3756775 3199790 6151017 6151128

NUMBER PLATE FITTMENT

6151046 3751313 6151128 6151256

WINCH COVER FITTMENT

6151046 6191013 6522048 6151255

BOLT M6 X 16mm

NUT FLANGE M6

WASHER M10 BZ

NUT FLANGED

SCREW CAP M10X30 ZP

BRACKET STD CONTROL BOX IN PAN

TRIM PLATE FOR 16500LB CONTROL

BOLT M6 X 16mm

NUT FLANGE M6

WASHER M6

BRACKET NO.PLATE

NUT FLANGE M6

SCREW M6 S/STEEL BUTTON HEAD

WASHER M6

EXTRUSION WINCH COVER @ 1757

PANEL WINCH COVER

BOLT M12 X 40mm 4581050 4581049

WASHER SPRING M12

WASHER FLAT M12

BAR TO MOUNT ASSEMBLY

6151321 6151232 6151189

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NUT M10 FLANGED

BOLT SEMS M10 X 30mm

NUT M12x1.75

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6821151R

INDICATOR ASSY RHS

INDICATOR ASSY

RETAINER FENDER LINER

FOG LAMPS

6821151L

6151308 6821116 6821152

180701 180302

3756948R

3756948L

6151300 6151213 4581082 3756949 6821189 6151300 6151017 6151046 4581036

INDICATOR ASSY LHS

SCREW SELF TAPPING

NUT NYLON PLUG

LOOM

SCOTCH LOCKS

CABLE TIE

PLATE RETAINER FENDER LINER

NUT CAGED M6

BOLT M6X20 BZ

WASHER M6 BZ

ADAPTER BRACKET

GROMMET

NUT CAGED M6

BOLT M6 X 16

WASHER M6

WASHER SPRING M6 3162457 3162456

LIGHT APERTURE MOLDING RH

LIGHT APERTURE MOLDING LH

*** NOTE:

Ø FOR IPF OPTIONAL FOG LAMPS, ORDER SUPPLIMENTARY KIT# 9381FCK.

Ø IF REFITTING OE FOG LAMPS, ADAPTER BRACKETS ARE SUPPLIED STANDARD WITH

THIS BULL BAR FITTING KIT TO MOUNT THESE LAMPS.

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REMOVAL OF BUMPER

1. If fog lights fitted in bumper, undo fog light loom connection (connection located on LHS of bumper)

2. Remove bumper by undoing 4 x M12 nuts on ‘U’ bolts through chassis and withdrawing bumper off chassis mount position, set aside. Retain bumper retaining ‘U’ bolts and nuts.

Note: For 2500 turbo diesel shown (and 3500 TD), undo and remove intercooler top mount bolts and rubber suspension blocks, this will allow the intercooler to tip back at the top and clear of the bumper U bolts allowing removal).

3. If OE fog lights fitted and are required for refitment into bull bar, remove each light and bracket assembly and then remove lights as shown by prising the lug each side from the case and undoing the adjuster screw.

4. Also, if OE fog lamps are to be reused, remove fog lamp loom fitted to bumper for reuse.

Prise open to remove lug

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FITTING PROCEDURE GENERAL

FOR 1500 MODEL VEHICLES FOLLOW STEPS 5 - 11, FOR 2500 AND 3500 VEHICLES STEPS 12 – 18.

5. Fit mount brackets to chassis rails and using existing U bolt sets, refasten.

6. Bracket set on vehicle.

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Warning: Drilling operations can result in flying

metal debris, safety glasses should be worn.

Warning: Drilling operations can result in flying

metal debri

s, safety glasses should be worn.

FITTING PROCEDURE GENERAL

7. Create a starter point with Dia 10.0mm drill using pilot hole in mount bracket for alignment. This will be a guide for Dia 7.0 through hole, which will in turn be used to create a guide hole for Dia 19.0mm hole saw Step 9.

8. Using the 7.0mm drill, drill right through both sides of the chassis.

Warning: Drilling operations can result in flying metal debris, safety glasses should be

9. Use the Dia 19.0 hole saw, as shown, with

7.0mm hole as a guide to drill a hole through outer wall of chassis.

10. Then, as shown, using a Dia 10.0 drill, drill hole through inner wall of chassis.

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OF CHASSIS

BETWEEN FLANGES

Warning: Drilling operations can result in flying

metal debris, safety

glasses should be worn.

FITTING PROCEDURE GENERAL

11. As shown, fit M10x100 bolt, sleeve, M10 x 3mm washer and flange nut and do up tight.

Note: Bolt head and washer outboard as shown, nut to be on inside face of bracket.

2500 AND 3500 ONLY STEPS 12 - 18

12. Fit chassis brackets as shown.

DRILL DIA

12.0mm

APPROX. 35mm FROM UNDERSIDE

13. Insert original U bolts, entering from inboard face of chassis (you may have to tilt intercooler to gain sufficient clearance to allow U bolt to enter this side).

14. Set brackets so front edge is vertical then do bolts up tight.

15. Replace the intercooler suspension blocks and bolts if removed for U bolt removal.

16. Mark the position for the pinning hole centrally between the body mount bracket flanges as shown on the outboard face of the chassis rails.

17. Drill through both sides of chassis and mount bracket flange Dia 10.0mm. **CAUTION

18. Fit M10 x 100 pinning bolt, M10 x 3MM washer and flange nut set and do up tight.

LOCATE CENTRALLY

CAUTION: TAKE CARE NOT TO DRILL THROUGH INTO THE RADIATOR ON THE INSIDE OF CHASSIS.

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FITTING PROCEDURE GENERAL

19. Remove lights from cartons and then remove screws and speed nuts from each light. These fasteners are not to be reused – new screws are supplied in the fitting kit

20. Insert nylon nuts into square holes in light

brackets inside wing area

21. Fit lights using screws supplied in fitting

kit, taking note of RH and LH light bodies, they are different and must be placed on the correct side of bull bar.

22. Fit large eyebolt nut into the plate on the

inside of the bar.

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FITTING PROCEDURE GENERAL

23. Screw in the eyebolt using the large

washer. Eyebolt can be positioned to sit vertically by rotating the large nut to the correct position

NOTE: EYEBOLTS SHOULD BE REMOVED FOR SAFETY REASONS WHEN TRAVELLING ON PUBLIC ROADS.

24. When the large nut is in its final position,

secure with the nut retaining bracket using an M6 bolt, washer and flange nut.

25. Secure the number plate bracket using

M6 bolts, flat washers and flange nuts. Attach the longer side to the bullbar and the shorter side to the number plate.

Note: As supplied from Warn, the winch handle

on 1500 and 16500lb winches should be in

the position as shown. This is correct

orientation for this bar.

26. Remove cable retaining band and position cable loop so it will go through roller fairlead

when it is placed in bull bar.

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FITTING PROCEDURE WINCH

Fit control box to pan:

• For 9500-12000lb winches, use universal control box bracket supplied, attaching to rear of control box mount studs.

• Slide bracket flange under pan and align with mount slots.

27. Fasten in position with 2 x M10 cap screws, black washers and flange nuts

• For 15000lb winches, use Warn supplied control box bracket, attaching to rear of control box mount studs.

• Slide bracket flange under pan and align with mount slots.

28. Fasten in position with 2 x M10 cap screws, black washers and flange nuts.

• For 16500lb winches, apply Sikaflex (or similar product) to rear of control box trim plate from fitting kit (note orientation critical to suit final position with control box profile in pan opening).

• Position trim plate on top of pan centrally about control box opening and line up with mount slots.

29. Fasten in position with 2 x M10 cap screws and flange nuts from fitting kit.

30. In some cases, the roller fair lead bracket must have a second set of holes drilled to line up with holes in winch bracket. If required, mark out as shown and using a 13.0 mm drill bit, drill two holes as shown in diagram.

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FITTING PROCEDURE WINCH

31. Viewed from front of vehicle the winch clutch (handle) must be positioned on the LH side (same side as smaller square access hole in pan). Cable must spool from the bottom of winch. Draw off enough cable so cable crimp can be pulled through roller fairlead.

32. Bolt winch in position with the roller fair lead in place.

Hint: To increase access to mount bolts in front of roller fairlead, remove circlips from bottom of each vertical roller shaft, push shaft up so roller can be dislodged sideways. Do up bolts in fairlead and winch, then refit circlip.

33. Connect the winch control box cables to the winch motor. Refer to the Warn handbook for additional information. Connect the long winch + & - cables to the vehicle after the bar is installed. Refer to the Warn winch

manual for vehicle wiring instructions.

34. Fitting number plate – with winch

Bolt number plate to the bracket with the M6 X 16mm bolts and M6 flange nuts through the lower holes of the number plate.

If not fitting winch.

Bolt the number plate through the top holes using M6 X 16mm bolts and M6 flange nuts.

35. If not fitting winch cont.

36. Wrap rubber extrusion around winch cover.

37. Place washers over the winch cover fixing holes located on the top middle face of the winch bumper.

38. Place the winch cover on top of the winch bumper inline with the mount holes.

39. Bolt together using the M6 button head stainless steel screws and M6 nuts.

View from above, rear of bull bar

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Warning: Drilling operations can result in flying

metal debris, safety glasses should be worn.

FITTING PROCEDURE BAR ON VEHICLE

40. Using two people, three if winch fitted, position the bar assembly on the vehicle mounts.

Caution: This product is heavy, especially if a winch is fitted. Do not attempt to lift it and fit it by yourself. Have some assistants help you or use a mechanical aid such as this hydraulic lift table as shown.

40. Bolt the bar to the mounts using M12 bolts, large flat washers and spring washers. Bolt the bar to the mounts using M12 bolts, large flat washers and spring washers. Align the bar to the profile of the guards, grille and light profile and tighten all bolts.

41. When bar is aligned, tighten bolts.

42. Using the M10 pilot holes in mount brackets, drill pinning hole through uprights on bull bar. Fit M10 screw, washer set and flange nut and do up tight.

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FITTING PROCEDURE BAR ON VEHICLE

If fitting optional accessory fog lamps kit 9381FCK follow fitting instructions supplied with kit. If fitting OE fog lights follow steps 43 –

48.

43. Fit M6 cage nuts and grommet to adaptor bracket as shown.

44. Fit light to adaptor bracket by locating mount lugs in light body into holes in adaptor bracket flanges.

45. Screw adjuster into grommet so that light is approximately parallel to bracket.

46. Fit adapter bracket and fog lamp assembly into brackets in bull bar wings, as shown.

47. Bolt in place with M6 x 16 bolt and washer sets into cage nuts.

48. Route OE fog lamp loom and connect to lamps.

Fitting plastic fog lamp aperture moldings.

49. If fog lamps are fitted, cut centre panel out of light aperture moldings using a hack saw blade.

50. If fog lamps are not fitted leave centre panel in place.

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FITTING PROCEDURE BAR ON VEHICLE

51. Note that the aperture moldings are handed (RH or LH), select correct hand for each wing aperture. Apply Sikaflex to recess in aperture molding flange then fit to aperture in wing. Use adhesive tape to secure plastic mold while Sikaflex cures.

52. Use adhesive tape to secure plastic mold while Sikaflex cures.

53. Wire up indicators and running lamps. Wire loom extensions are supplied in fitting kit.

54. If winch fitted, fit off winch hook.

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FITTING PROCEDURE BAR ON VEHICLE

55. Trim fender liner with air hacksaw or similar tool along line as shown. Cut away the outboard flap, which normally fits in the end of the bumper wing. This is so the liner can be held back easily by the retaining bracket at step 56.

Cut along this path

56. Fit liner retainer bracket with black M6 bolt and washer sets into M6 cage nuts in wing returns each side as shown.

FITTED PRODUCT ON 1500 MODEL

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