ARB 3932020 User Manual

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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.

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

WINCH/NON WINCH BUMPER TO SUIT LANDROVER DISCOVERY 2003 ON

PRODUCT NUMBER 3932100

FITTING KIT NUMBER 6172409

TOP TUBE & BUFFER KITS:
5100040: Top Tube Kit
5100020: Buffer Kit – With hole (required when fitting Top Tube)
5100030: Buffer Kit – With No Hole

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.

• 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.

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USE

PART No

QTY

DESCRIPTION

3756531

1 PAIR

BRACKET MOUNT

6151106

4

BOLT ½” x 5” UNC

4581049

8

WASHER FLAT ½”

MOUNTING SYSTEM

4581050

4

WASHER SPRING ½ ”

6151138

4

NUT ½” UNC

6151243

4

BOLT M10 x 130 X X1.5

4581040

8

WASHER M10 FLAT

4581048

4

WASHER SPRING M10

6151026

6

NUT M10 x 1.5

5846402

1 PAIR

PACKERS L/RHS

6151232

10

BOLT M10 x 30 x 1.5mm

BAR TO

4581048

10

WASHER SPRING M10

MOUNTING SYSTEM

4581040

12

WASHER FLAT M10

6151026

2

NUT M10 x 1.5

6151017

4

BOLT M6 x 16mm

37651313

1

BRACKET NUMBER PLATE

NUMBER PLATE

6151046

4

WASHER FLAT M6

6151128

4

NUT FLANGE M6

BUFFER KIT (5100020 REQUIRED IF FITTING

TOP TUBE)

3162469 L/R

1 PAIR

BUFFERS L/RHS

4581072

12

WASHERS FLAT LARGE
6151162

12

NUT NYLOC M6

BUFFER KIT (5100030 REQUIRED IF NOT

FITTING TOP TUBE)

3162466L/R

1 PAIR

BUFFERS L/RHS

4581072

12

WASHERS FLAT LARGE

6151162

12

NUT NYLOC M6

6821151 L/R

1

ARB INDICATOR KIT

INDICATOR & FOG LIGHT

3756563 L/R

1 PAIR

BRKT FOG LIGHT

6151017

4

BOLT M6 x 16mm

4581072

4

WASHER FLAT M6
5848283

2

PACKERS PLASTIC FOG LIGHT SPACERS

180302

12

BLACK CABLE TIES

PT003-12B

6

SCREW COVER ( FOG LAMP )

6151308

10

SCREW SELF TAPPING ( TURN & FOG )

6821116

4

NYLON PLUG ( TURN SIGNAL BRACKET )

6821152

2

WIRING LOOM ( TURN SIGNAL )
6151309

6

CAPTIVE U TYPE - CLIP

6151315

4

CAGE NUT M6

4581036

4

WASHER SPRING M6

180701

6

SCOTCH LOKS

6131174

1

TOP TUBE

TOP TUBE

6151255

2

BOLT M12 x 40

(5100040)

4581049

2

WASHER FLAT M12
4581050

2

WASHER SPRING M12

6521031

1

PANEL WINCH COVER

COVER FOR NON WINCH BAR

6151256

2

SCREW M6 S/STEEL BUTTON HEAD
6151046

2

WASHER FLAT M6
6151128

2

NUT FLANGE M6
6191005

1

WINCH COVER EXTRUSION

6151180

2

BOLT M6 x 20

UNDER GUARD TRIM TO BAR

4581084

2

WASHER BODY FLAT M6
6151128

2

NUT FLANGE M6

PARTS BELOW TO BE USED IN A WINCH BAR

4581040

4

WASHER FLAT M10

8-9000lb WINCH

6151074

2

BOLT 1 ¾” x 3/8” UNC
180302

8

CABLE TIES

6151021

2

BOLT M8 x 20mm

CONTROL BOX BRACKET

4581044

2

WASHER FLAT M8
3756209

1

CONTROL BOX BRACKET
6151132

2

NUT FLANGE M8

TOOLS REQUIRED.

BASIC TOOL KIT, DRILL, 10MM DRILL BIT ( 180mm long) STANLEY KNIFE AND A METRIC TAPE.

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ASSEMBLY SEQUENCE .

PLEASE READ AND UNDERSTAND FITTING INSTRUCTIONS BEFORE

ATTEMPTING TO FIT BAR TO VEHICLE

1. To remove the bumper bar from the vehicle

undo the 7 screws that hold the plastic guard
liner to the bumper bar on each side. Undo the
four nuts that hold the bumper to the
aluminum brackets and loosen the two nuts
located on the inside out board face.
Disconnect the fog lamp harness from both
lamps and with assistance pull the bumper bar
forward enough to disconnect the head lamp
washers.

2 Remove the aluminum chassis extension

brackets from both sides. Remove the
tubular cross brace and the recovery
bracket. Both are refitted at a later stage.
Undo the 5 screws that hold the plastic air
shield in place and with a small flat blade
screw driver remove the two yellow plugs
from the under side of the chassis rails.

3. Drill holes out to ½” through chassis rails and
tow hook.

4. Fit the new impact absorbers to both the LH &
RH chassis rails. Note that the smooth face
faces outwards with hole on the inside. Using
the ½” hardware supplied, bolt the RH
impact absorber into position. At this stage
only the two horizontal bolts are fitted, repeat
this on the LH side using the ½” hardware
supplied.

5. Once the impact absorbers are sitting
horizontal and at the same height tighten both
bolts. The holes in the impact absorber
bottom bracket should line up with the square
holes in the chassis. Before drilling the
vertical pinning bolts measure the distance
between the two out side edges of the impact
absorber – making sure the measurement is
no larger than 807 mm (loosen bolts and
adjust if necessary).

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6. When drilling the vertical pinning bolt THE
DRILL MUST BE STRAIGHT IN BOTH
DIRECTIONS. Failure to do so will result in
damage to the radiator mounting system. Drill
out both holes and assemble using the long
M10 bolts and hardware supplied. From the
out board side of the chassis insert the chassis
packers between the under side of the chassis
and the impact absorber with the finger tab
facing downward. Repeat this on the LHS.

This picture shows how to fit chassis packer in
between chassis bracket and chassis rail.

Picture is of RHS of vehicle

7. The plastic air shield needs to be trimmed

before being replaced, cut the holes (located
on the edge tabs) into an open ended slot.
Place the shield back into its original position
and screw across the back edge in 3 locations.
The edge tabs are now pushed in on top of the
spacer, the tabs are retained when the vertical
bolts are done up between the chassis and the
chassis spacer.

Re – confirm the measurement between

the impact absorbers and tighten all of
the vertical bolts.

8. Remove the horizontal bolts only, as previously
described in step 3. Re – assemble but this time
the tubular cross brace and the original
recovery point are attached.

Note: the recovery bracket is located to the left

hand chassis rail.

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9. Placing the original bumper bar face down
on a blanket remove all of the screws that hold
the painted outer section to the main bumper.
Using pliers remove the clip that holds the
washer nozzle in the bumper and take out the
nozzle (both sides). These are re-fitted into the
bar once the fog lamp and turn signal are
installed.

Using a small flat bladed screw driver dis­engage the locking tabs on both sides and
remove the cover, this will enable the fog lamp
to be un-screwed in three places and removed.

10. Fit the “u” nuts to the fog lamp bracket as
shown, the nylon washer fits between the
bracket and the lamp mounting foot
(located on the adjustment side) fit the fog
lamp with the screws provided.

Note:- The Left hand fog lamp is shown.

Insert the nylon plugs into the square holes

in the turn signal aperture, located on the
inside face of the bar. From the rear,
screw the turn signal assembly to the
bracket on the bar.

Re-fit the washer nozzle both sides once the

fog lamp & turn signal are fitted. The
washer retaining clip may need to be
flattened slightly to fit.

NYLON PLUG

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IF NOT FITTING WINCH

11. Wrap rubber extrusion around winch cover.

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

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

Bolt together using the M6 button head

stainless steel screws and M6 nuts.

14. Fit buffers to bar using 6mm hardware.

IMPORTANT

1. Sahara Bumper has no large top hole

2. If fitting Sahara Bumper go to step 16

15. Fit the top tube through the hole in the top of
the buffer and secure from underneath using
M12 x 40mm bolt, spring washer and flat
washer.

NOTE This step for Sahara Bar only

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TO FIT WINCH INTO BAR

16. If vehicle is to be fitted with a winch, follow
the next steps.

Handle is in normal position

17. Rotate handle 144° counter clockwise.

18. Stand winch upright and undo the capped

head screws and by lifting the gearbox only a
couple of millimetres, rotate the gearbox.
Once in position, refit all screws and tighten
firmly.

WARNING

Do not lift gear box more than a couple of

millimetres.

19. Drill out roller fairlead 25mm lower than

original hole using a 12mm drill bit.

NEW HOLES

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20. Fit control box bracket to bar using 8mm
hardware.

21. Fit winch into bar using 1 1/2” x 3/8”
bolt on top holes and 1 ¾” x 3/8” bolt on the
lower holes plus 25mm large flat washers and
spring washers.

Cable spools from bottom of winch.

When fitting roller fairlead to bar,
remove circlips and push vertical
pins upward to move the vertical
rollers sideways to enable you to
place a socket to the bolt. When all
bolts are fitted replace vertical
pins and circlips.

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22. Fit control box to bracket and connect all
power cables to winch motor as per warn
instructions.

23. Connect ground wire to winch tension bar.

24. Cable tie all cables together and keep clear of
sharp edges and all moving parts.

When bar is fitted to vehicle, fit both
power cables to battery and cable tie to

vehicle keeping clear of all moving parts.

25. With assistance lift the bar into position
and slide it over the two impact absorbers.
Once in position bolt up the bar in the 8
places using the M10 bolts & hardware
supplied, finger tight only at this stage.

Adjust the bar on the vehicle until a uniform

gap is achieved to the grille & headlamp
and guards. Once happy with the position of
the bar tighten all of the bolts.

The bar is then drilled and pined in its
final position using the M10 hardware
supplied as shown in the attached photo.

26.Re-connect the fog lamp harness and the
turn signal harness on both sides of the
vehicle, cable tie the wiring where
appropriate.

Ensure the turn signal & fog lamps are
working correctly.

Reconnect the head lamp washer tubes on

both sides.

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.

27. Trim the plastic inner guard liners by
aligning with the bar and using the hole in the
wing as a guide, drill a 6 mm hole and secure
with the M6 hardware supplied

28. Fit number plate to number plate bracket

using 6mm hardware in this position.
Place double sided tape on rear of number
Plate to stop any vibration.

29. Fit number plate to bar using 6mm hardware

using the outer holes of number plate.
Place double sided tape on rear of number
Plate to stop any vibration.

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