ARB 3936020 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]

WA: [phone] NSW: [phone] ACT: [phone] SA: [phone] QLD: [phone] NT: [phone] TAS: [phone]

ARB WINCH/NON WINCH BUMPER TO SUIT FORD F250/350 PICKUPS
2000 MODELS ON.

PRODUCT No. 3936120

FITTING KIT No. 6172410

TOP TUBE & BUFFER KITS:
5100175: Top Tube Kit
5100171: Buffer Kit – With hole (required when fitting Top Tube)
5100172: 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.

• 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 ATTEMPED.

• 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.

Note :
1 If fitting optional fog lights, fitting kit no. 9381FCK is required.
2 This winch bumper is suitable for Warn 15,000lb winch only.

Tools Required

Metric Spanner and Socket set, Phillips head screwdriver, 12.5mm &10mm drill bit
and drill.

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USE

PART No

QTY

DESCRIPTION

BUFFER FITTMENT

(5100171 REQUIRED IF FITTING

TOP TUBE)

6151128

12

NUT FLANGE M6

3162153 1 BUFFER LHS
3162154 1 BUFFER RHS

BUFFER FITTMENT

(5100172 REQUIRED IF NOT

FITTING TOP TUBE)

6151128

12

NUT FLANGE M6

3162471L 1 BUFFER LHS
3162471R 1 BUFFER RHS

TOP TUBE FITTMENT

6151255 2 BOLT M12 X 40mm

(5100175)

4581049 2 WASHER FLAT M12
4581050 2 WASHER SPRING M12
6131232

1

TOP TUBE

LOWER BUFFER FITTMENT

3162175 1 BUFFER LOWER
6151128 5 NUT FLANGE M6

MOUNT BRACKETS TO VEHICLE

3756501L

1

BRACKET BAR MOUNT LHS

3756501R

1

BRACKET BAR MOUNT RHS

3193695

4

PLATE
6151321 8 M10 FLANGED NUT
4581011

8

WASHER M12 X 4mm THICK
6151232 8 BOLT M10 X 30mm
4581048 8 WASHER M10 SPRING
6151255 6 M12 x 40 BOLTS
4581049

12

FLAT WASHER M12
4581050 6 WASHER SPRING M12
6151305 6 NUT CAGED M12

WINCH

4581044 4 WASHER M8 x 17 x 1.2

180302

4

CABLE TIE

BLB850 2 BATTERY LEAD BLACK

BLR850 1 BATTERY LEAD RED

TOW HOOK REPLACEMENT

4581049 6 M12 WASHER FLAT
4581050 6 M12 WASHER SPRING
6151255 6 BOLT M12 X 40
6151189

4

NUT M12

CONTROL BOX FITTMENT

3756499 1 CONTROL BOX BRACKET
6151021 2 BOLT M8 X 20mm
4581044

2

WASHER, FLAT M8 x 17 x 1.2

180302

4

CABLE TIE

6151132 2 NUT FLANGE M8

EG50 2 GROMMET RUBBER

NUMBER PLATE FITTMENT

6151017 2 BOLT M6 X 16mm
6151128 2 NUT FLANGE M6
6781408 1 TAPE DOUBLE SIDED

AIR DEFLECTOR FITTMENT

6151022 3 BOLT M8 x 25
4581063

3

WASHER FLAT M8 x 25.4 x 3
6151301 3 NUT M8 CAGED
6522022 1 AIR DEFLECTOR PANEL
4581046 3 WASHER M8 SPRING

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TENSION BRACKET

3756432 2 TENSION BRACKET
6151255 4 BOLT M12 X 40mm
4581050 4 WASHER SPRING M12
4581007

8

WASHER FLAT M12 LARGE

6151189

4

NUT M12

WINCH COVER FITTMENT

6151128 2 NUT FLANGE M6
6151256

2

SCREW M6 S/STEEL BUTTON HEAD

6191006

1

WINCH COVER EXTRUSION
6522023 1 WINCH COVER
6151046 2 WASHER M6

BAR TO MOUNT ASSEMBLY

6151255 4 BOLT M12 X 40mm
4581050 4 WASHER SPRING M12
4581007

4

WASHER FLAT M12 LARGE
4581048 4 WASHER SPRING M10
6151321 4 NUT M10 FLANGED
6151232 4 BOLT M10 X 30mm
4581040 4 WASHER FLAT 3/8”

LIGHT SURROUNDS TO BAR

3162456 1 LIGHT SURROUND LHS
3162457 1 LIGHT SURROUND RHS

CB

3162152 2 PLASTIC PLUG DIA16

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ASSEMBLY SEQUENCE FOR WINCH BUMPER.

1. Position the lower buffer on the winch bumper
and assemble using the M6 flange nuts. (do
not over-tighten)

2. Insert the side buffers through the holes and
fix using the M6 flange nuts. (do not
overtighten)

If fitting optional fog lights, do so now.

Refer to the instructions provided in the fog
light kit.

3. Push the top tube through the hole in the
buffer and fasten using the M12 x 40mm bolts,
washers and spring washers.

Go to step 4 if not fitting top tube

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4. Remove the bumper and two recovery hooks.

Fit M12 cage nuts to slots on each mount
bracket as shown and fit mount brackets onto
chassis ends, gusset should locate inside
chassis end.

Using M12 x 40mm bolts, flat washers, spring
washers, re-fasten through the holes where
the recovery hooks were removed, do not
tighten bolts.

5. Fasten brackets with the M10 bolts, large 4mm
thick washers, M10 spring washers, M10
flange nuts and plates, finger tight only.

Note: The plates mount to the front
face of the bull bar mounting bracket
as shown.

6.

With the bull bar mounting brackets now in
place (but not tightened) bolt the tension strap
to the chassis using the hole next to the
horizontal slot.

Using the M12 bolt, thick washers, spring
washer and nut bolt up the tension strap as
shown.

The tension strap will need to be bent out
slightly, to pass alongside the bull bar
mounting bracket.

As the bolt is tightened the bracket will bend
slightly to allow the strap to sit flat against the
chassis.

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7.

Bend the end of the strap inward, as shown, to
allow the strap to sit against the bull bar
mounting bracket.

Drill through the strap and bracket using a

12.5mm drill bit and bolt up using the same
hardware as described in the above step.

IMPORTANT: STRAP POSITION MUST BE
AS LOW AS PRACTICAL ON MOUNT
BRACKET AS SHOWN.

8. If fitting winch.

The clutch handle must be repositioned so it is
in a convenient location when mounted to bar.

Place the winch on its end and remove all
gearbox bolts.

Gently raise the motor just enough to rotate it.
Viewing from the gearbox end, rotate the
gearbox 72deg clockwise.

Do not completely remove the motor and avoid
damaging the gasket.

Refit and tighten all bolts.

Note: Take care not to lift the assembly more
than a couple of millimeters while rotating to the
desired position to avoid un-meshing the gears.

9.

If fitting winch.

The three control box leads, which connect to
winch, need to be replaced with the longer
leads supplied in the fitting kit. Replace the
leads with the same colours.

Bolt the control box bracket to the control box,
refer photo.

Fit the two grommets into the round holes then
thread the cable through.

Mount the control box bracket onto the top
pan, using M8 bolts, flat washers and flanged
nuts. Use the cables ties to ensure the winch
cables are secure, tying them together.

ORIGINAL POSITION

NEW POSITION

ROTATION

Drill Dia

12.5mm hole
for pinning

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10.

The roller fair lead must be drilled prior to
fitment.

Using a 13.0 mm drill bit drill two holes as
shown in diagram.

11.

If fitting winch.

Viewed from front of vehicle the winch clutch
must be positioned on the LH side. Cable
spools from the bottom. Bolt in position with
the roller fair lead in place. Draw off some
cable so cable crimp can be pulled through
roller fairlead.

If crimp is too large to fit through, remove a
circlip from a horizontal roller, partially remove
the shaft so roller gap is increased and feed
cable and crimp through. Refit shaft and
circlip. Bolt in position with the roller fair lead
in place.
Note; 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.

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.

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12.

Fitting with winch

Fitting without winch

If fitting with winch.

Peel off one side of the double sided tape and
adhere to the top rear side of the number
plate. Note: Clean the adhering surfaces
before applying tape with an alcohol solvent.

Peel off the other side of the tape and bolt to
the winch bumper with the M6 X 16mm bolts
and M6 flange nuts through the lower holes of
the number plate.

Press firmly to the top of the number plate so
the tape can properly adhere.

If not fitting with winch.

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

If desired the double sided tape can be used
down the sides of the number plate.

13. If not fitting winch.

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.

14.

Remove the rubber air guide and discard.

IMPORTANT :- When fitting a winch, on some
models the top power steering cooler line (
steel ) will interfere with the winch and must be
bent down to provide clearance as shown .

Take care when bending the cooler line
tube that you don’t kink it.

Leave the power steering cooler in its original
position.

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15. Bolt the deflector to the original bolts located in
the chassis cross member.

Tie the power steering lines to the chassis
away from sharp edges and moving parts with
cable ties provided.

16. Using two people, three if winch fitted, position
the bar assembly on the vehicle mounts. Make
sure the deflector is held down for the bar to
be pushed back.

17. Bolt the bar to the mounts using M12 bolts,
large flat washers and spring washers. Align
the bar to the profile of the guards and tighten
all bolts including the mount brackets.

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18. The bar must be pin bolted to the mount
brackets. Using a drill and 10mm drill bit, drill
through the upper and lower Ø10mm holes
located in the mount brackets.

Fasten the holes using M10 bolts, flat washers
and spring washers.

19. Fit three M8 cage nuts to square holes inside
the bar. Bolt the deflector to the bar using M8
bolts, large M8 flat washers and spring
washers.

20. Bolt the tow hooks to the mount brackets using
the M12 x 40mm bolts, flat washers and spring
washers.

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21. If fitting with winch

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

22. If you have fitted the optional fog lights, the
base of the fog light surround must be
removed. Carefully cut the 4 retaining tabs with
a knife.

Glue the light surrounds to the bar using a
silicone based rubber adhesive. Run the bead
along the cavity on the rear side of the part.
Position the surround to align the inside edge
with the buffer and concentric to the light.

Wipe off any adhesive on the front face of the
bar. Allow adhesive to cure before continuing.

23. There are two Ø16 holes located on the top
face of the bar. If no CB aerials are fitted the
holes can be covered with the plastic plugs
provided in the fitting kit.

Place the ARB logo on the front face of the bar
in the indentation.

24. If fitting fog lights, wire the fog lights as described in the fog light fitting instructions.

The fog lights can be adjusted to desired angles by the adjustment bolts located at the back of the light
insert. When adjustment is finalized, be sure to retighten the fog light bolts.

If fitting with winch.

25. Connect the long winch + & - cables to the vehicle after the bar is installed.

Refer to the Warn winch manual for vehicle wiring instructions.
Ensure that these 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.

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