ARB 3462010 User Manual

ARB COMBINATION WINCH, NON-WINCH BULL BAR TO SUIT
CHEVROLET SILVERADO 99-02 1500 MODELS.

PRODUCT No. 3462010, WITH FITTING KIT 3562010

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.

Note :

• This bull bar is suitable for Warn 9,500-16,500lb winches.

• Fog light provisions are in lower pan area of bull bar. IPF840FYS lights

are suitable for this location.

Tools Required

Metric Spanner and Socket set Allen key set
Phillips head screwdriver Dia 15/64”, 10.0 and 12.0mm drill bits
Electric drill 13mm chuck Sikaflex 227 adhesive, black color

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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.

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

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

USE PART No QTY DESCRIPTION

MOUNT BRACKETS TO VEHICLE 3756752L 1 BRACKET BAR MOUNT LHS

3756752R 1 BRACKET BAR MOUNT RHS
3756767 2 BRACKET CAGE NUT
6151321 2 NUT M10 FLANGED
4581040 2 WASHER M10
6151232 2 SCREW M10 X 30mm
4581048 2 WASHER M10 SPRING
4581049 10 M12 WASHER FLAT
4581050 8 M12 WASHER SPRING
6151255 8 BOLT M12 X 40
6151244 2 BOLT M12X150
6151189 4 NUT M12x1.75
6151305 4 NUT M12 CAGE SUIT 4MM
3756766 2 BRACKET SPACER
5811037 2 SLEEVE

WINCH 180302 8 CABLE TIE

TOW HOOK RELOCATION 6151365 2 EYEBOLT M24 2.5 SWL

6151361 2 NUT M24 GR8 ZP
3756765 2 BRACKET NUT RETAINING
4581300 2 WASHER M24 EYEBOLT
6151046 2 WASHER M6
6151017 2 BOLT M6 X 16mm
6151128 2 NUT FLANGE M6

CONTROL BOX FITTMENT 4581291 2 WASHER M10 BZ

6151321 2 NUT FLANGED
6151364 2 SCREW CAP M10X30 ZP
3756775 1 BRACKET STD CONTROL BOX IN PAN
3199790 1 TRIM PLATE FOR 16500LB CONTROL

NUMBER PLATE FITTMENT 6151017 4 BOLT M6 X 16mm

6151128 4 NUT FLANGE M6
6151046 4 WASHER M6

WINCH COVER FITTMENT 6151128 2 NUT FLANGE M6

6151256 2 SCREW M6 S/STEEL BUTTON HEAD
6151046 2 WASHER M6
6191013 1 EXTRUSION WINCH COVER @ 1757
6522048 1 PANEL WINCH COVER

3751384 1 BRACKET NO.PLATE

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BAR TO MOUNT ASSEMBLY 6151255 6 BOLT M12 X 40mm

4581050 6 WASHER SPRING M12
4581049 12 WASHER FLAT M12
4581048 2 WASHER SPRING M10
6151321 2 NUT M10 FLANGED
6151232 2 BOLT M10 X 30mm
4581040 2 WASHER FLAT 3/8”
6151189 6 NUT M12x1.75

INDICATOR ASSY 6821151R 1 INDICATOR ASSY RHS

6821151L 1 INDICATOR ASSY LHS
6151308 4 SCREW SELF TAPPING

6821116 4 NUT NYLON PLUG
6821152 2 LOOM
180701 6 SCOTCH LOCKS
180302 4 CABLE TIE

INNER GUARD RETAINER 3199787R 1 PLATE INNER GUARD

3199787L 1 PLATE INNER GUARD
6151128 4 NUT FLANGE M6
6151213 4 SCREW M6X20 BZ
4581082 4 WASHER M6X20 BZ

NOTE: Shipping brackets connecting
bull bar to pallet and associated
fasteners are not intended to be reused
in fitted bar assembly.

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ASSEMBLY SEQUENCE FOR WINCH BUMPER.

1. FITTING MOUNTING BRACKETS

1.1 Remove the plastic shroud above the
radiator as shown, by releasing plastic
clips

1.2 To remove the grille, undo four fasteners a
¼ turn, then release top headlights so you
can prize the outer strips free from the
retainer clips in the guard area.

1.3 If winch is to be fitted, trim section, as
shown by white area, off LH chassis
end area, this is necessary to clear
terminal on winch motor.

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1.4 Remove the bumper by undoing 2 bolts on
the outer rear stabilizer arms, unclip any
lights, then undo the 4 bolts from top.

Remove tow hooks and stabilizer arms

1.5 Position the mount brackets as shown on
the end of the chassis rails. Fit an M12
bolt and washer set as shown finger tight
only.

M12 x 150
bolt and
nut set

1.6 Fit M12 x 150 bolt through outer hole in
bracket and through existing horizontal
tow hook holes in the chassis. Do not
tighten.

1.7 Make sure that the bracket is square to
the chassis and back hard against the
chassis mount face.

Using a 12mm drill bit, drill vertically down
through both the top chassis plate and top
of the chassis. Use the hole in the chassis
bracket as a pilot hole

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1.8 Remove bracket and fit spacer under
flange next to M12 weld nut lining up with
drilled hole as shown with M12 bolt and
washer set.

1.9 Fit M12 cage nut to small access bracket
and put into place up inside chassis end
for holding spacer bracket in position,
screw M12 bolt in finger tight.

1.10 Fit M12 cage nut to large mount bracket
as shown and fit back into position. Make
sure the LH and RH brackets are parallel
to each other

1.11 When fitting M12x150 bolt set, slide
sleeve over bolt inside chassis to stop
crush of chassis. Fit nut and washer and
nip up (not tight). Fit M12 bolt and washer
set from bottom of chassis into M12 cage
nut.

Sleeve

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1.12 Fit M12 bolt, nut and washer set into
spacer, and M12 bolt and washer set into
top of bracket and flange and nip up (not
tight)

1.13 Fit M10 bolt, nut and washer set into

gusset and do up tight.

Tighten all other bolts starting from long
bolt through chassis, bolt from underneath,
top bolts etc.

1.14 Check that brackets are still parallel to
each other, if not adjust and tighten bolts.

Fit grille and shroud back into
position.

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2. PREPARING BULL BAR FOR FITTING

2.1 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.

2.2 Insert nylon nuts into square holes in light
brackets inside wing area

2.3 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.

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2.4 Fit large eyebolt nut into the plate on the
inside of the bar.

2.5 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.

2.6 When the large nut is in its final position,
secure with the nut retaining bracket using
an M6 bolt, washer and flange nut.

2.7 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.

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3. IF FITTING WINCH

3.1 From the factory the winch handle should
be in the position as shown.

Remove cable retaining band and position
cable loop so it will go through roller
fairlead when it is placed in bull bar.

3.2 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.

• 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.

• Fasten in position with 2 x M10 cap

screws, black washers and flange nuts.

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• 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.

• Fasten in position with 2 x M10 cap screws

and flange nuts from fitting kit.

3.3 On some models, the roller fair lead must
be drilled prior to fitment.

Mark out as shown and using a 13.0 mm
drill bit, drill two holes as shown in
diagram.

3.4 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.

Hint: If crimp is too large to fit through, remove
a circlip from a horizontal roller, partially
remove the shaft so roller gap is increased and
feed cable and crimp through. Refit shaft and
circlip.

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.

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
installed. Refer to the Warn winch manual

for vehicle wiring instructions.

the bar is

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3.5

Fitting with winch, number plate above RFL

Fitting without winch, number plate covers RFL

opening

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.

3.6 If not fitting winch cont.

Wrap rubber extrusion around winch
cover.

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

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

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

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