Last Rev Date: 17/05/2007
Page 1 of 10
Fitting instructions# 3783284
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
Part Number
Product
Description
Suited to
vehicle/s
Fitting Kit
Number
4450200
SIDE RAIL
2 DOOR (SWB)
6172268
4450210
SIDE RAIL
4 DOOR (LWB)
6172253
WARNING
ALSO, NOTE 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.
♦ 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: 17/05/2007
Page 2 of 10
Fitting instructions# 3783284
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
FITTING REQUIREMENTS
REQUIRED TOOLS FOR FITMENT OF PRODUCT:
Basic Tool Kit
Drill
Round Hand File
11 mm Drill Bit
6.5mm Drill Bit
HAVE AVAILABLE THESE SAFETY ITEMS WHEN FITTING PRODUCT:
Protective eyewear
Hearing protection
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
M10
44Nm
32lbft
M12
77Nm
57lbft
Last Rev Date: 17/05/2007
Page 3 of 10
Fitting instructions# 3783284
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
PARTS LISTING
APPLICATION.
PART NO.
QTY
DESCRIPTION
3199987L
1
PLATE ANGLE LH (LWB)
3199987R
1
PLATE ANGLE RH (LWB)
6151412
12
M6 X 16 BUTTON HEAD CAP SCREW
4584295
12
M6 WASHER BLACK
ANGLE TRIM TO VEHICLE (LWB)
6151128
8
M6 FLANGE NUT
3199988L
1
PLATE ANGLE LH (SWB)
3199988R
1
PLATE ANGLE RH (SWB)
6151412
8
M6 X 16 BUTTON HEAD CAP SCREW
4584295
8
M6 WASHER BLACK
ANGLE TRIM TO VEHICLE (SWB)
6151128
4
M6 FLANGE NUT
3199943
2
CAGE PLATE M10 (225mm)
6151304
2
CAGE NUT M10
6151204
2
BOLT M10 X 35mm
4581040
2
WASHERS M10
FRONT MOUNT BRACKET TO
CHASSIS (LHS & RHS)
4581048
2
SPRING WASHERS M10
3199943
2
CAGE PLATE M10 (225mm)
3199848
2
CAGE PLATE M12
6151304
2
CAGE NUT M10
6151305
2
CAGE NUT M12
4581040
2
WASHERS M10
4581007
2
WASHERS GOLD M12
4581048
2
SPRING WASHERS M10
4581050
2
SPRING WASHERS M12
6151255
2
BOLT M12 X 1.75 X 40mm
REAR MOUNT BRACKET TO
CHASSIS (LHS & RHS)
6151232
2
BOLT M10 X 30mm
3199944
4
CAGE PLATE M10 (335mm)
6151304
4
CAGE NUT M10
4581040
4
WASHERS M10
4581048
4
SPRING WASHERS M10
MIDDLE MOUNT BRACKET TO
CHASSIS (LHS & RHS)
6151204
4
BOLT M10 X 35mm
6151098
2
BOLT M12 X 1.5 X 40
4581007
4
WASHER / PACKER M12 GOLD
FRONT MOUNT BRACKET
(LHS & RHS) MANUAL
TRANSMISSION VARIANT
4581050
2
SPRING WASHER
MISCELLANEOUS
215637
6500002
2
2
STICKER “ARB”
RUBBER PLUG 60.3mm TUBE
Last Rev Date: 17/05/2007
Page 4 of 10
Fitting instructions# 3783284
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
FITTING PROCEDURE
1. Remove the original side steps from the
vehicle by removing existing four nuts (A) from
side step studs along sill.
2. Remove two existing bolts (B) and carefully
remove side rail with help of another person.
WARNING – Only remove one side at a
time.
3. Place rubber plugs supplied into the end of the
side rails.
4. Remove all the bolts which go through to
the sill of the vehicle. Like the one shown in
the photograph on the left.
A
B
Last Rev Date: 17/05/2007
Page 5 of 10
Fitting instructions# 3783284
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
5. Using the black M6 dome head bolts plus
M6 black flat washer, loosely fit the sill
cover. Some of the holes pick up on
existing holes with weld nuts behind them,
some pass through existing holes but
require a flange nut to be fitted on the inside
of the sill, and some holes will have to be
drilled.
6. For the holes which have to be drilled, use
a centre punch to mark the position of the
hole in the centre of the slot in the sill cover.
7. Remove the sill cover and drill through the
sill using a 6.5mm drill. Tough up the bare
metal in the hole with black paint.
8. Remove the sill cover to prevent damage to
it during drilling operations later.
NOTE: The sill covers get refitted at the end
of the installation process.
9. For automatic vehicles, support the weight of
the gearbox cross member with stand or
similar. Remove and retain existing bolt for
front bracket.
10. For the rear mounting bracket, fit a M12 cage
nut into one of the M12 cage nut plates and
make appropriate bend in cage plate to reach
through the hole shown and position the cage
nut behind the hole the M12 bolt will pass
through. As shown in photo on left.
11. With the assistance of another person, hold
side rail against chassis.
12. Using a M12 x 1.75 x 40 bolt(course thread),
M12 spring washer and M12 Gold washer
loosely fasten into place.
NOTE: Leave this bolts finger tight at this
stage.
Last Rev Date: 17/05/2007
Page 6 of 10
Fitting instructions# 3783284
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
13. Fasten Front Bracket to vehicle as shown.
(For Auto vehicles, use the bolt removed in
step 8)
Note: For manual vehicles use Bolt M12 X 1.5 X
40 (fine pitch), M12 Gold washer and M12 spring
washer which are supplied in fitting kit. Use extra
M12 Gold washer as packer between chassis
and Front Bracket. (Some manual vehicles are
fitted with a steel fuel pump cover which secures
to the chassis with this bolt. If this is the case, do
not use the extra M12 gold washer as a packer
between the chassis and the rail bracket.)
14. While pushing the side rail to get the
vertical face of the front mounting bracket
as close to the side of the chassis as
possible, tighten up the bolt “A”.
15. Using a marker, mark the position of the
hole in the vertical side of the chassis for
the front bracket.
16. While using a jack or a leaver, push the centre
mounting bracket up against the bottom of the
chassis. (In the direction of the arrow)
17. Using a marker, mark the position of the hole
in the side of the chassis rail for the centre
bracket. (Do not mark or drill the hole in the
bottom of the chassis rail at this stage.)
A
Mark and drill this
hole only
Last Rev Date: 17/05/2007
Page 7 of 10
Fitting instructions# 3783284
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
18. Use a centre punch to mark the centre of
the marked hole for the front bracket. Then
using an 11mm drill bit, drill the hole. Be
carefull, as depending on the size of your
drill, the bit will tend to wonder upwards
from the market position.
Remove any sharp burs, and touch up the
bare metal with black paint to prevent
corrosion.
19. Use a centre punch to mark the centre of
the marked hole for the centre bracket.
Then using an 11mm drill bit, drill the hole.
Be carefull, as depending on the size of
your drill, the bit will tend to wonder
upwards from the market position.
Remove any sharp burs, and touch up the
bare metal with black paint to prevent
corrosion.
Refit the side rail as follows.
20. Fit the M12 bolt through the hole into the
bottom of the chassis rail.
21. Fit an M10 cage nut into M10 cage nut
plate and make appropriate bends in cage
nut plate to reach the hole in the top of the
front bracket.
22. Insert cage nut plate through chassis hole
as shown and line up cage nut with hole
and bracket.
23. Using an M10 x 35 bolt, M10 spring washer
and M10 x 25 flat steel washer loosely
fasten into place.
Warning: Drilling operations can result in
flying metal debris, safety glasses should be
Warning: Drilling operations can result in
flying metal debris, safety glasses should be
Last Rev Date: 17/05/2007
Page 8 of 10
Fitting instructions# 3783284
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
24. For the centre bracket, fit M10 cage nut
into M10 cage nut plate and make
appropriate bends in cage nut plate to reach
the hole.
25. Insert cage plate through the hole in the
chassis as shown and line up cage nut with
hole and bracket.
26. Using a M10 x 35 bolt, M10 spring washer
and M10 x 25 flat steel washer loosely
fasten into place.
27. While pushing up on the centre bracket to
make sure that it is up against the bottom of
the chassis rail, tighten the bolt shown.
28. For the rear bracket, fit an M12 cage nut into
one of the M12 cage nut plates and make
appropriate bends in the cage nut plate to
reach through the hole shown and position the
cage nut behind the hole the M12 bolt will
pass through. As shown in photo on left.
29. Using a M12 x 40 bolt, M12 spring washer and
M12 Gold washer loosely fasten into place.
Last Rev Date: 17/05/2007
Page 9 of 10
Fitting instructions# 3783284
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
30. Using an 11mm drill bit, drill through the
bottom of the chassis, using the hole in the
bottom of the centre bracket as a guide.
31. Clean off any sharp burs, and treat the
bare metal surfaces with paint to prevent
corrosion.
32. Fit an M10 cage nut into M10 cage nut
plate and make appropriate bends in cage
nut plate to reach the hole in the bottom of
the chassis member.
33. Use an M10 x 35mmbolt, flat and spring
washer to fasten the bottom of the centre
bracket to the chassis.
34. Using an 11mm drill bit, drill through the
bottom of the chassis, using the hole in the
bottom of the rear bracket as a guide.
35. Clean off any sharp burs, and treat the
bare metal surfaces with paint to prevent
corrosion.
36. Fit an M10 cage nut into M10 cage nut
plate and make appropriate bends in cage
nut plate to reach the hole in the bottom of
the chassis member.
37. Use an M10 x 30mm bolt, flat and spring
washer to fasten the bottom of the rear
bracket to the chassis.
38. Finally, refit the sill cover, using the black
M6 dome headed bolts, flat washers and
flange nuts as required.
Warning: Drilling operations can result in
flying metal debris, safety glasses should be
Warning: Drilling operations can result in
flying metal debris, safety glasses should be
Last Rev Date: 17/05/2007
Page 10 of 10
Fitting instructions# 3783284
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
39. Fit ARB Sticker to rails at the location shown.
40. Tighten all bolts to recommended torque.
41. Break off all protruding cage nut plates from
chassis.
Repeat for the other side of vehicle.
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