ARB 3932020 User Manual
13/6/08
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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: (03) 9761 6622 Fax: (03) 9761 6807
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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