ARB 5611210 User Manual

ARB TOYOTA 80 SERIES

REAR STEP TOW BAR

Product number: 5611210

Optional

Wheel

Optional

Jerry Can

Carrier

Carrier

Left Hand Side

of vehicle (LHS)

Rear Step Tow Bar

Right Hand Side
of vehicle (RHS)

READ FITTING INSTRUCTIONS

CAREFULLY BEFORE PROCEEDING

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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.

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

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

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USE PART No QTY DESCRIPTION

FIT TAIL LIGHT ASSEMBLIES

TO REAR BAR

6821172L 1 Tail Light Assembly – Left Hand Side (LHS)

6821172R 1 Tail Light Assembly – RHS

6151017 12 Bolt M6 x 16
6151128 8 Nut M6 flange
6151300 4 Nut M6 cage
6151046 12 Washer 6mm flat
3756681 2 Light mount cover bracket

FIT CAGE NUTS TO REAR

BAR

6151300 16 Nut M6 cage
6151303 4 Nut M8 cage

3756701 2 Locking pin bracket

FIT LOCKING PIN BRACKETS

TO REAR BAR

6151022 4 Bolt M8 x 25
6151132 4 Nut M8 flange
4581044 4 Washer 8mm flat

FIT LOOM TO VEHICLE 6821163 1 Loom

6151096 2 Bolt M12 x 40 x 1.25
4581049 4 Washer 12mm flat

FIT BAR TO REAR CROSS

MEMBER

4581050 4 Washer 12mm spring
3199773 2 Cross member nut plate
6151306 2 Nut M12 cage
6151255 2 Bolt M12 x 40 x 1.75

6151097 4 Bolt M12 x 50 x 1.25
6151340 2 Bolt M12 x 50 x 1.75
4581007 6 Washer ½” flat heavy duty gold zinc

FIT BAR TO UNDERSIDE OF

CHASSIS

4581050 6 Washer 12mm spring
5848309 2 Chassis packer front
5848310 2 Chassis packer rear
3199772 1 Chassis lower nut plate
6151306 2 Nut M12 cage

6151255 4 Bolt M12 x 40 x 1.75
4581007 4 Washer ½” flat heavy duty gold zinc

FIT BAR TO CHASSIS SIDE

4581050 4 Washer 12mm spring
3199771 2 Chassis side nut plate
6151306 4 Nut M12 cage

6522646 1 Centre cover panel
6151300 2 Nut M6 cage
6151352 2 Socket head cap screw M6 x 25 stainless steel

FIT CENTRE COVER PANEL

6151207 2 Bolt M6 x 25
6151046 4 Washer 6mm flat
6151042 4 Washer 6mm spring
5848302 2 Packer black nylon
6250003 2 Spacer 8mm thick gold zinc

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FIT END SURROUNDS TO

REAR BAR

FIT END SURROUND

BRACES

3131192L 1 End surround LHS

3131192R 1 End surround RHS

6151083 6 Bolt M8 x 35
6151132 6 Nut M8 flange
4581044 6 Washer 8mm flat
6250003 6 Spacer 8mm thick gold zinc

3756757L 1 End surround brace LHS

3756757R 1 End surround brace RHS

6151017 2 Bolt M6 x 20
6151046 2 Washer Flat M6
6151128 2 Nut Flange M6
6151083 4 Bolt M8 x 35
6151021 4 Bolt M8 x 20
6151132 4 Nut M8 flange
4581044 8 Washer 8mm flat
4581046 8 Washer 8mm spring
3199774 1 Wing brace nut plate
6151303 2 Nut M8 cage

3162478L 1 Vertical trim

3162478R 1 Vertical trim

3162482L 1 End surround trim

FIT URETHANE TRIMS

3162482R 1 End surround trim

6821166 2 Reflector
6151162 10 Nut M6 nyloc
4581082 10 Washer 6mm flat heavy duty black zinc

3199769 1 Top infill plate

FIT TOP INFILL PLATE

3199727 1 Aluminium step plate
4590019 1 Rubber extrusion seal
6151256 10 Button head cap screw M6 x 16 stainless steel

4761132 1 Gooseneck

FIT GOOSENECK

55010 1 Pull pin
55020 1 Spring Clip

FIT TRAILER PLUG 6151370 2 Screw M4 x 20 plastite pan head

PARTS SUPPLIED WITH THIS KIT TO BE USED WHEN FITTING WHEEL CARRIERS OR JERRY CAN CARRIERS

FITTING NUMBER PLATE

LIGHT

86060BL 1 Number plate light
6151281 2 Screw M5 pan head
6151282 2 Nut M5 flange

3756677 1 Centre locator bracket
6151255 2 Bolt M12 x 40 x 1.75

FIT CENTRE LOCATOR

4581049 4 Washer 12mm flat
4581050 2 Washer 12mm spring
6151189 2 Nut M12 x 1.75

TOOLS REQUIRED: Basic tool kit, 30mm socket, ¼” drive socket set, silicon.
TORQUE SETTINGS: 6mm – 9Nm, 8mm – 22Nm, 10mm – 44Nm, 12mm – 77Nm

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FITTING TAIL LIGHTS TO BAR

1. Compile components as shown.

- Light assembly (LHS shown)

- Light cover

- 6 x M6 x 16mm bolts

- 6 x M6 flange nuts

- 2x M6 cage nuts

- 6 washers to suit M6

2. Fit cage nuts to light cover as shown.

Outside of car

When fitting light assemblies to bar,

orange (indicator) lights must be to

the outside as shown. The flange on

the bracket should also be at the top.

Orange light

3. Feed looms through large hole in bar.

4. Fit light assemblies using M6 hardware.
Finger tighten only.

5. Repeat steps 1 to 3 for RHS assembly.

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FITTING CAGE NUTS TO BAR

6. Fit M6 cage nuts
to light mount cover
bracket as shown.

7. Using M6 x 16 bolts and flat washers, fit
cover bracket to light mount.

8. Tighten only cover bracket bolts securely.

9. Fit M6 cage nuts (9 total) in square holes in
top of bar as shown.

M6

M6

10. Fit M6 cage nuts (6 total) and M8 cage nuts

M8

M6

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M8

(4 total) to front of bar. (RHS shown)

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FITTING LOCKING PIN BRACKETS TO BAR

Flange nuts this side

11. Fit locking pin brackets using two M8 x 25
bolts, flat washers and flange nuts. Finger
tighten only.

Fit bolts through from rear of rear bar so
that the flange nuts are on the same side
as the bracket as the photo shows.

(Viewed from front of bar LHS.)

REMOVING BUMPER

12. M8 bolts must fit in rear of bar for ease of
adjustment later on.

(Viewed from rear of bar LHS.)

13. To fit Rear Bar to vehicle, remove bumper
bar, mud flap and tow bar (if fitted) from
vehicle.

OPTIONAL
Paint lower rear quarter panel satin black.

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FITTING LOOM TO VEHICLE

14. Fit loom inside rear cross member of
vehicle chassis.

The plug for connecting the loom to the
vehicle must be on the RHS of the
vehicle.

Trailer plug wires

LHS

Tail light

connector

with

yellow

RHS

Tail light

connector

with green

wire

15. Exit tail light wires and trailer plug wires as
shown.

The tail light connectors with the
GREEN wire must be on the RHS of the
vehicle.

The tail light connectors with the
YELLOW wire must be on the LHS of the
vehicle.

16. The loom is fitted with wiring for a number
plate light.

If a jerry can carrier is to be fitted the
number plate and light should be fitted to it.
The wire for the number plate light must be
on the same side of the vehicle as the jerry
can carrier.

Number plate

light wires

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If a wheel carrier is to be fitted without a
jerry can carrier the wire for the number
plate light should be on the same side of
the vehicle as the wheel carrier.

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17. Make sure when plug is connected to
vehicle that wire is cable tied well clear of
muffler and exhaust components that may
melt it.

FITTING REAR BAR TO VEHICLE

18. If a wheel carrier or jerry can carrier is not
to be fitted a cover panel must be fitted.

If cover panels are to be fitted

they must be fitted to the bar

before it is fitted to the vehicle.

Refer to fitting instructions supplied in
cover panel fitting kit for fitment of
cover panel.

19. Fit 8mm cage nuts to wing brace nut
plate and insert into LHS of vehicle and
align with rear holes in side of chassis

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20. With the help of a friend to hold the
previously fitted nut plate in the correct
position, fit the LHS end surround brace to
the side of the chassis rail using M8 x
35mm bolts, spring washer and flat
washer., finger tighten only.

21. Whilst working on the LHS, fit M12 x 1.75
caged nuts into side plates, and fit plate
as to press wing brace nut plate arm
against the inside of the chassis rail to
stop any rattling when the rear bar is fitted
to vehicle.

NB FIT CAGE NUTS TO SIDE

PLATES SO PLATES ARE

HANDED.

22. Fit M12 x 1.75 cage nuts to chassis side
plates and insert into end of chassis rails.

NOTE:

After bar is fitted and bolts are tightened
in these chassis side plates, the handles
must be bend over so that struts are not
damaged when wheel carriers or jerry can
carriers are closed.

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23.

Fit 2 x M12 x 1.75 cage nuts into plate and
insert into inside RHS chassis rail and
align with underside of chassis holes.

Bend rear handle of nut plate to enable

24.

plate to fit flat on the inside of chassis rail.

25. On RHS of vehicle remove exhaust
hanger bracket from vehicle and remove
rubber isolater body from muffler for ease
of fitment later.

26. Using M8 x 35mm bolts, spring washers
and flat washers, secure side surround
brace to rear holes in side of chassis
rails.

27. Refit rubber isolater body back to muffler
and to the side surround brace.

FINGER TIGHTEN ONLY

28. Fit M12 x 1.75 cage nut into rear cross
member nut plate and fit to both sides of
rear cross member.

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PHOTO IS LHS OF VEHICLE

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29. Slide bar onto rear of chassis leaving
enough room to plug main loom into tail
light assemblies on either side of vehicle.

30. When this is done push bar onto chassis

until centre mount of bar is flush up against
chassis cross member.

31. Fit two M12 x 40 x 1.25 bolts, spring
washers and flat washers as shown into
centre mounting bracket.

(Finger tighten only.)

32. Fit 3 x M12 x 40mm x 1.25 (fine thread)
bolts, spring washers and large gold
colored flat washers to underside of
chassis rails to LHS of vehicle

(Finger tighten only.)

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M12 X 1.25 X 50 BOLTS

( FINE THREAD )

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To the RHS of the vehicle, fit 2 x M12 x 1.75 x
50 ( coarse thread ) bolts, spring washer and
flat large gold coloured washer to the most
forward hole. To the rear hole, fit 1 x M12 x

1.25 x50 bolt, spring washer and flat large gold

coloured washer

M12 X 1.75 X 50 BOLTS

M12 X 50 X 1.25 BOLT

33. Fit two M12 x 40 x 1.75 bolts, large gold
coloured flat washers and spring washers
into captive nut plates (installed previously
step17) on each side of vehicle.

(Finger tighten only)

Align nut plates using handle that protrudes
through cut out in rear of bar.

34. Before tightening any bolts you must fit the
8mm packers in between the rear bar and
the vehicle chassis. The double cut out
packers to the rear of the bar, and the
single cut out packers to the front of the
bar. When these packers are fitted, tighten
all bolts firmly.

ARROWS INDICATE WHERE
PACKERS ARE TO BE FITTED

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35.

. The single cut out packers to the front of
the bar. (As viewed from front of vehicle )
When these packers are fitted, tighten all
bolts firmly.

Bend handle over

36.

Bend over handles of nut

plates so that struts are

not destroyed when wheel

carriers or jerry can carriers

are closed.

AT THIS STAGE JERRY CAN CARRIERS OR WHEEL CARRIERS MUST BE FITTED.

TO FIT JERRY CAN CARRIERS AND WHEEL CARRIERS, REFER TO FITTING

INSTRUCTIONS SUPPLIED IN FITTING KITS WITH JERRY CAN CARRIERS OR WHEEL

CARRIERS.

IF A JERRY CAN CARRIER OR WHEEL CARRIER IS NOT TO BE FITTED, THE COVER

PANEL SHOULD BE ALREADY FITTED. (REFER TO STEP 16.)

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FITTING CENTRE COVER PANEL

Black nylon washer

37. Compile the components as shown

- Centre cover panel

- 2 x M6 cage nuts

- 2 x M6 x 25 socket head cap screw
stainless steel

- 2 x M6 x 25 bolts

- 4 x 6mm flat washers

- 2 x black nylon packers

- 2 x 8mm thick gold zinc spacers

- 4 x 6mm spring washers

38. Place M6 cage nuts into lower section of
centre cover panel.

39. Fit two M6 x 25 stainless steel socket
head cap screws, flat washers and spring
washers through top flange inside cover
panel as shown.

40. Place black nylon spacers on screws on
outside of centre cover panel flange and
attach to captive nuts in rear bar.

M6 cage nuts

(Finger tighten only.)

41. Place 8mm spacer between underside of

centre cover panel and rear bar.

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42. From underneath rear bar pass two M6 x
25 bolts, flat washers and spring washers

through the aligned parts and finger
tighten.

M6 x 25 bolt and flat washer

FITTING END SURROUNDS TO REAR BAR

Top RHS

43.

Align faces of centre cover panel with
wheel carrier, jerry can carrier or cover
panel and tighten securely.

44. The surrounds are attached to rear bar
using three M8 x 35 bolts, flat washers
and flange nuts per side.

45. Place bolts and flat washers through the
top two holes of the rear bar end plate as
shown.

M8 flange nut

M8 x 35 bolt

and washer

46. Fit 8mm spacer to bolts, then fit end
surround and secure finger tight with M8
flange nuts.

8mm spacer

47. Fit the lower bolt with washer, spacer and
nut in the same sequence as the upper
two.

(Finger tighten only)

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48. Using M8 x 20 bolts, flat washers and
flange nuts secure end surrounds to braces
finger tight. (RHS shown.)

VIEWED FROM RHS OF VEHICLE.

49. Before tightening bolts fit urethane vertical
trim between end plate and end surround.

50. Adjust trim to fit snugly around the rear bar

and the end surround.

51. Align top face of end surround parallel with
body of vehicle.

52. Starting in the top corner of the end
surround and working backwards tighten all
bolts.

A second person may be required to help
keep the vertical trim fitting snugly and to
ensure the end surround remains parallel
to the body.

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53. Fit reflector to end of buffer.

54. Fit urethane buffer to top of end surround
using M6 nyloc nuts and large black flat
washers.

When fitting washers to studs under end
surround smear flat washers with grease to
hold them in place as shown below.

Reflector

FITTING TOP INFILL PLATE AND ALUMINIUM STEP PLATE

55. Using M6 button head cap screws fit top

infill plate.

56. To fit rubber sealing strip to underside of

aluminium step plate, lay strip on the
underside of step plate and place so over
hang is even on both ends. Using scissors,
cut darts up to the bulb end of the rubber
strip, so the strip can follow the front profile
of the aluminium step plate.

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57. Carefully remove backing tape on the
rubber strip and fit to step plate working
from the centre outwards. Make sure
rubber strip hugs the front edge of the
aluminium step plate.

Using M6 button head cap screws fit

58.

aluminium step plate

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FITTING TRAILER PLUG AND GOOSENECK

59. Fit trailer plug to recess using M5 pan head
screws as shown by arrows.

For aesthetics and protection of the plug it
is recommended that a flat type plug is
fitted.

To fit alternate plugs an adaptor bracket
(part number 5700090) is available. This is
not supplied as standard with the rear bar
kit.

60.

Fit gooseneck with pull pin and spring clip
as shown.

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