ARB 3462020 User Manual

ARB COMBINATION WINCH, NON-WINCH BULL BAR TO SUIT CHEVROLET SILVERADO 03 ON 1500 MODELS.

PRODUCT No. 3462020, WITH FITTING KIT 3562040

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: (08) 9244 3553 NSW: (02) 9821 3633 ACT: (02) 6280 7475 SA: (08) 8244 5001 QLD: (07) 3872 3872 NT: (08) 8947 2262 TAS: (03) 6331 4190

Head Office – ARB Corporation Ltd VIC: 42-44 Garden Street, Kilsyth, Victoria, 3137 Tel: (03) 9761 6622 Fax: (03) 9761 6807

USE PART No QTY DESCRIPTION

MOUNT BRACKETS TO VEHICLE 3756785L 1 BRACKET BAR MOUNT LHS

3756785R 1 BRACKET BAR MOUNT RHS 3199796 2 PLATE CAGE NUT 4581049 10 M12 WASHER FLAT 4581050 8 M12 WASHER SPRING 6151255 6 BOLT M12 X 40 6151244 2 BOLT M12X150 6151189 2 NUT M12x1.75 6151305 4 NUT M12 CAGE SUIT 4MM 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

3751384 1 BRACKET NO.PLATE

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

WASHER BOTTLE PROTECTION 6131349 1 FRAME ASSY WASHR BOTTLE PROT

6151303 2 NUT CAGED M8 SUIT 1.6-3.2 6151022 2 BOLT M8X25 4581044 2 WASHER FLAT M8 4581046 2 WASHER SPR M8 6151232 2 BOLT M10X30 4581040 2 WASHER FLAT M10 4581048 2 WASHER SPR M10

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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, carefully push the retainer spring clips back out in four places behind grille. Pull outer bar from between headlights forward to release from clip into end of guard. NOTE: It may

be necessary to remove top headlights to gain access to these clips if you cannot release them easily.

1.3 Remove bumper by undoing four bolts from above and behind bumper then two bolts securing bumper to wing support braces from under and behind forward of wheel arch area.

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1.4 Remove stabilizer arms both sides

1.5 Remove plastic shrouds around chassis

1.6 Remove tow hooks

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1.7 Fit cage nuts to bracket tangs as shown

1.8 Position the mount brackets as shown on the ends of the chassis rails (LHS shown). Loosely fit an M12 bolt and washer set to top bolt position and lower position as shown finger tight only.

Inserting sleeve

Sleeve in position

1.9 Partly withdraw M12 x 150 bolt and fit crush sleeve over bolt body inside chassis as shown. Fit flat and spring washers, and nut. Do not tighten.

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1.10 Fit M12 cage nuts to both bent plates, 1 x LH and 1 x RH as assemblies are opposite for each side of vehicle. Insert nut assembly through large hole in underside of chassis and up to meet vacant hole above long bolt. Insert M12 bolt and washer set, do up finger tight.

1.14 Check that brackets are parallel to each other, if not adjust. When parallel then tighten all bolts (nominal outside dimension across brackets is 898mm).

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.

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

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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 flange to the bullbar and the shorter flange to the number plate.

2.8 Fit the M8 cage nuts to the square holes in

the wing brace on the LHS (washer bottle side) of the bull bar. The body of the cage nuts are to be on the inside of the brace. These nuts are to be used to fasten the washer bottle protection arm to the bull bar.

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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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4. FITTING BULL BAR TO VEHICLE

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

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.

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.

4.2 Trim excess plastic inner guard molding to meet lower profile of bull bar wing. Note the position of water bottle on LHS of vehicle and trim neatly around it.

4.3 Fit washer bottle protection frame to

lower mounts where original bumper stabiliser arms were located using 2 x M10 x 30 bolt and washer sets. Fit off the upper bracket to inner wing area of bull bar as shown using M8 x 25 bolts and washer sets.

NOTE: The 2 x M8 cage nuts should be in place from step 2.7.

4.4 Fit inner guard plates to ends of bull bar wings and fasten with M6 black screws and washers.

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4.5 If fitting with winch

With the winch cable through the roller fair lead. Mount the hook to the end of the cable.

4.6 Wire up the indicator and clearance lamp assemblies. Use scotch locks to splice cables to existing indicator and clearance lamp wiring and cable tie securely.

If fog lights are to be installed, mount positions are on lower pan area between winch opening and high lift jack position.

Refer to the Warn winch manual for vehicle wiring instructions.

Ensure that electrical cables are installed well clear of sharp, hot or moving objects. Secure the winch cables to the vehicle and winch bumper with the supplied cable ties.

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