ARB 3462040 User Manual

3/27/09 Page 1 of 1 AP0016

720 SW 34

th

Street

AIR L OCK E R, I N C. Renton, WA 98057

4 x 4 A cce s sor i es Tel: 425 264 1391 | Fax: 425 264 1391

www .arb u sa.co m

APPLICATION CHART

GMC SIERRA 2003-2007 CLASSIC COMBINATON BULLBAR

Part Number: 3462040

APPLICATION CHART

Vehicle Description

Fitting Kit No.

3562040

3562050

3562060

SIERRA (not Denali)

2003-2007 CLASSIC C/K 1500



2003-2007 CLASSIC C/K 1500HD



2003-2007 CLASSIC C/K 2500



2003-2007 CLASSIC C/K 2500HD



2003-2007 CLASSIC C/K 3500



YUKON (not Denali)

2003-2006 K1500



2003-2006 XL



Part Number:

Product

FITTING KIT 3562040: For fitting Bull bars - 3462020 or 3462040

ARB COMBINATION WINCH, NON-WINCH BULL BAR

Description: Suited to

vehicle/s:

CHEVROLET SILVERADO & GMC SIERRA 03 TO 07 CLASSIC 1500 MODELS.

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 sales@arb.com.au North & South American enquiries sales@arbusa.com Other international enquiries exports@arb.com.au

www.arb.com.au

Last Rev Date: 24/7/07 Page 1 of 16 Fitting instructions# 3783176

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 set Allen key set Phillips head screwdriver Dia 5.5, 10.0 and 12.0mm drill bits Electric drill 13mm chuck Sikaflex 227 adhesive, black color

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.

FASTENER TORQUE SETTINGS:

SIZE Torque Nm Torque lbft

M6 9Nm 4lbft

M8 22Nm 16lbft

M10 44Nm 32lbft

Hearing protection

M12 77Nm 57lbft

Note :

• This bull bar is suitable for Warn 12,000-16,500lb winches.

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

this location.

Last Rev Date: 24/7/07 Page 2 of 16 Fitting instructions# 3783176

PART No QTY DESCRIPTION

MOUNT BRACKETS TO

VEHICLE

WINCH 180302 8 CABLE TIE

TOW HOOK RELOCATION

CONTROL BOX FITMENT

NUMBER PLATE FITMENT

WINCH COVER FITMENT

WASHER BOTTLE

PROTECTION

PARTS LISTING

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

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

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

6151017 4 BOLT M6 X 16mm 6151128 4 NUT FLANGE M6 6151046 4 WASHER M6 3751384 1 BRACKET No. PLATE

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

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

Last Rev Date: 24/7/07 Page 3 of 16 Fitting instructions# 3783176

BAR TO MOUNT

ASSEMBLY

INDICATOR ASSY

INNER GUARD RETAINER

PARTS LISTING cont.

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

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

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: Silverado fitting photos shown, GMC Sierra is the same fitup detail.

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

Last Rev Date: 24/7/07 Page 4 of 16 Fitting instructions# 3783176

FITTING MOUNTING BRACKETS

1. Remove plastic shroud above radiator as shown, by releasing plastic clips

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.

3. If fog lamps are fitted to bumper, undo electrical connections.

4. 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.

Last Rev Date: 24/7/07 Page 5 of 16 Fitting instructions# 3783176

FITTING MOUNTING BRACKETS

5. Remove stabilizer arms both sides

6. Remove plastic shrouds around chassis

7. Remove tow hooks

Last Rev Date: 24/7/07 Page 6 of 16 Fitting instructions# 3783176

FITTING MOUNTING BRACKETS

8. Fit cage nuts to bracket tangs as shown

9. 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

10. 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.

Last Rev Date: 24/7/07 Page 7 of 16 Fitting instructions# 3783176

FITTING MOUNTING BRACKETS

11. 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.

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

13. Fit grille and shroud back into position.

Last Rev Date: 24/7/07 Page 8 of 16 Fitting instructions# 3783176

PREPARING BULL BAR FOR FITTING

14. 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.

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

16. 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.

HINT: It may be an advantage at this stage to rough in the wiring for indicators (Step

46) while the bull bar is not yet fitted.

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

Last Rev Date: 24/7/07 Page 9 of 16 Fitting instructions# 3783176

PREPARING BULL BAR FOR FITTING

18. Screw in the eyebolt after first fitting 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.

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

20. 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.

Last Rev Date: 24/7/07 Page 10 of 16 Fitting instructions# 3783176

WINCH FITMENT

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

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

23. Fit control box to pan:

• For 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.

Last Rev Date: 24/7/07 Page 11 of 16 Fitting instructions# 3783176

WINCH FITMENT

24. 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).

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

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

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

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

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

28. 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.

29. 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.

30. 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.

Last Rev Date: 24/7/07 Page 12 of 16 Fitting instructions# 3783176

WINCH FITMENT

Fitting with winch, number plate above RFL

Fitting without winch, number plate covers RFL

opening

Fitting number plate – with winch

32. 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.

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

If not fitting winch cont.

View from above, rear of bull bar

34. Wrap rubber extrusion around winch cover.

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

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

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

38. 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.

Last Rev Date: 24/7/07 Page 13 of 16 Fitting instructions# 3783176

FITTING BULL BAR TO VEHICLE

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

40. 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. 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.

Chassis fixing point

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

42. 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.

43. Fit washer bottle protection frame lower mount to where original bumper stabiliser arms were located using 2 x M10 x 30 bolt and washer sets. Fit off the other end 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 38.

Inner bar fixing point

Last Rev Date: 24/7/07 Page 14 of 16 Fitting instructions# 3783176

FITTING BULL BAR TO VEHICLE

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

If fitting with winch

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

46. 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.

47. 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.

Last Rev Date: 24/7/07 Page 15 of 16 Fitting instructions# 3783176

FINAL PRODUCT FITTED TO VEHICLE

Last Rev Date: 24/7/07 Page 16 of 16 Fitting instructions# 3783176

Part Number:

Product Description:

Suited to vehicle/s:

FITTING KIT 3562060:

For fitting Bull bars - 3462020 or 3462040

ARB COMBINATION WINCH, NON-WINCH BULL BAR

CHEVROLET SILVERADO & GMC SIERRA 03 TO 07 CLASSIC 2500HD-3500 MODELS.

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 sales@arb.com.au North & South American enquiries sales@arbusa.com Other international enquiries exports@arb.com.au

www.arb.com.au

Last Rev Date: 24/07/07 Page 1 of 14 Fitting instructions# 3783178

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 set Allen key set Phillips head screwdriver Dia 5.5, 10.0 and 12.0mm drill bits Electric drill 13mm chuck Sikaflex 227 adhesive, black color

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

Note :

• This bull bar is suitable for Warn 12,000-16,500lb winches.

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

for this location.

Last Rev Date: 24/07/07 Page 2 of 14 Fitting instructions# 3783178

PARTS LISTING

MOUNT BRACKETS TO

VEHICLE

WINCH

TOW HOOK RELOCATION

CONTROL BOX FITTMENT

NUMBER PLATE FITTMENT

WINCH COVER FITTMENT

BAR TO MOUNT

ASSEMBLY

INDICATOR ASSY

INNER GUARD RETAINER

PART No QTY

3756787L 1 BRACKET BAR MOUNT LHS

3756787R 1 BRACKET BAR MOUNT RHS

4581060 2 WASHER 13X30X3 4581049 14 M12 WASHER FLAT 4581050 8 M12 WASHER SPRING 6151255 8 BOLT M12 X 40 6151189 6 NUT M12x1.75 5848316 2 PACKER

180302 8 CABLE TIE 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 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 6151017 4 BOLT M6 X 16mm 6151128 4 NUT FLANGE M6 6151046 4 WASHER M6 3751384 1 BRACKET NO.PLATE 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 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 4 NUT M12x1.75

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

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

DESCRIPTION

Last Rev Date: 24/07/07 Page 3 of 14 Fitting instructions# 3783178

NOTE: Silverado fitting photos shown, GMC Sierra is the same fitup detail.

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

Last Rev Date: 24/07/07 Page 4 of 14 Fitting instructions# 3783178

FITTING MOUNTING BRACKETS

1. Remove plastic shroud above radiator as shown, by releasing plastic clips

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

3. Remove bumper stabilising arms located behind and outboard in bumper to chassis region.

4. Remove bumper undoing four bolts from above and behind bumper.

5. Remove and replace tow hooks on

opposite chassis sides.

Note: The hole underneath the chassis may need to be elongated to allow the bolt to fit into the rear underside position. Leave the outer bolt off for now.

Last Rev Date: 24/07/07 Page 5 of 14 Fitting instructions# 3783178

FITTING MOUNTING BRACKETS

6. Fit the mount brackets as shown, to the

end of the chassis rails, top M12 bolt and washer set as shown finger tight only.

7. Slide in ‘L’ shaped packer oriented as shown

8. Fit M12 bolt, spring washer and Dia

13.0x30x3 large washer into tow hook thread, insert M12 bolt and washer set in pinning hole to line up packer hole. Tighten up lower bolt.

9. Remove loose bolt from pinning hole and drill through using Dia12.0 drill. Then insert and do up M12 bolt set.

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

Last Rev Date: 24/07/07 Page 6 of 14 Fitting instructions# 3783178

FITTING MOUNTING BRACKETS

10. Drill pinning hole in top position as shown then insert and do up M12 bolt set.

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

11. Tighten up all bolts

12. Check that tops of brackets are horizontal and that brackets are parallel to each other.

13. Overall pitch should be 910-915mm.

14. If not release bolts and make necessary adjustments.

15. Refit grille and shroud.

Last Rev Date: 24/07/07 Page 7 of 14 Fitting instructions# 3783178

PREPARING BULL BAR FOR FITTING

16. 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.

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

18. 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.

HINT: It may be an advantage at this stage to rough in the wiring for indicators (Step 40) while the bull bar is not yet fitted.

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

Last Rev Date: 24/07/07 Page 8 of 14 Fitting instructions# 3783178

PREPARING BULL BAR FOR FITTING

20. 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

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

.

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

22. 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.

Last Rev Date: 24/07/07 Page 9 of 14 Fitting instructions# 3783178

FITTING WINCH

23. As supplied the winch handle should be in the position as shown.

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

25. Fit control box to pan:

• For 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.

Last Rev Date: 24/07/07 Page 10 of 14 Fitting instructions# 3783178

FITTING WINCH

• 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.

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

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

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

28. 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.

29. 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.

30. 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.

Last Rev Date: 24/07/07 Page 11 of 14 Fitting instructions# 3783178

FITTING WINCH

Fitting with winch, number plate above RFL

Fitting without winch, number plate covers RFL

opening

31. 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.

32. If not fitting winch.

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

33. 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.

View from above, rear of bull bar

Last Rev Date: 24/07/07 Page 12 of 14 Fitting instructions# 3783178

FITTING BULL BAR TO VEHICLE

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

35. 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.

36. 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.

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

37. 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.

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

If fitting with winch

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

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FITTING BULL BAR TO VEHICLE

40. 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.

41. 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.

FITTED PRODUCT

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Part Number:

Product Description:

Suited to vehicle/s:

FITTING KIT 3562060:

For fitting Bull bars - 3462020 or 3462040

ARB COMBINATION WINCH, NON-WINCH BULL BAR

CHEVROLET SILVERADO & GMC SIERRA 03 TO 07 CLASSIC 2500HD-3500 MODELS.

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 sales@arb.com.au North & South American enquiries sales@arbusa.com Other international enquiries exports@arb.com.au

www.arb.com.au

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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 set Allen key set Phillips head screwdriver Dia 5.5, 10.0 and 12.0mm drill bits Electric drill 13mm chuck Sikaflex 227 adhesive, black color

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

Note :

• This bull bar is suitable for Warn 12,000-16,500lb winches.

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

for this location.

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PARTS LISTING

MOUNT BRACKETS TO

VEHICLE

WINCH

TOW HOOK RELOCATION

CONTROL BOX FITTMENT

NUMBER PLATE FITTMENT

WINCH COVER FITTMENT

BAR TO MOUNT

ASSEMBLY

INDICATOR ASSY

INNER GUARD RETAINER

PART No QTY

3756787L 1 BRACKET BAR MOUNT LHS

3756787R 1 BRACKET BAR MOUNT RHS

4581060 2 WASHER 13X30X3 4581049 14 M12 WASHER FLAT 4581050 8 M12 WASHER SPRING 6151255 8 BOLT M12 X 40 6151189 6 NUT M12x1.75 5848316 2 PACKER

180302 8 CABLE TIE 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 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 6151017 4 BOLT M6 X 16mm 6151128 4 NUT FLANGE M6 6151046 4 WASHER M6 3751384 1 BRACKET NO.PLATE 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 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 4 NUT M12x1.75

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

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

DESCRIPTION

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NOTE: Silverado fitting photos shown, GMC Sierra is the same fitup detail.

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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FITTING MOUNTING BRACKETS

1. Remove plastic shroud above radiator as shown, by releasing plastic clips

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

3. Remove bumper stabilising arms located behind and outboard in bumper to chassis region.

4. Remove bumper undoing four bolts from above and behind bumper.

5. Remove and replace tow hooks on

opposite chassis sides.

Note: The hole underneath the chassis may need to be elongated to allow the bolt to fit into the rear underside position. Leave the outer bolt off for now.

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FITTING MOUNTING BRACKETS

6. Fit the mount brackets as shown, to the

end of the chassis rails, top M12 bolt and washer set as shown finger tight only.

7. Slide in ‘L’ shaped packer oriented as shown

8. Fit M12 bolt, spring washer and Dia

13.0x30x3 large washer into tow hook thread, insert M12 bolt and washer set in pinning hole to line up packer hole. Tighten up lower bolt.

9. Remove loose bolt from pinning hole and drill through using Dia12.0 drill. Then insert and do up M12 bolt set.

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

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FITTING MOUNTING BRACKETS

10. Drill pinning hole in top position as shown then insert and do up M12 bolt set.

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

11. Tighten up all bolts

12. Check that tops of brackets are horizontal and that brackets are parallel to each other.

13. Overall pitch should be 910-915mm.

14. If not release bolts and make necessary adjustments.

15. Refit grille and shroud.

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PREPARING BULL BAR FOR FITTING

16. 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.

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

18. 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.

HINT: It may be an advantage at this stage to rough in the wiring for indicators (Step 40) while the bull bar is not yet fitted.

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

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PREPARING BULL BAR FOR FITTING

20. 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

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

.

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

22. 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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FITTING WINCH

23. As supplied the winch handle should be in the position as shown.

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

25. Fit control box to pan:

• For 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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