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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
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
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
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
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
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
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
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
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
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