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
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
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
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
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
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
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
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
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
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
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
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
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
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
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
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
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
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
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
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
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
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
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
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
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
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
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
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