ARB 5620010 User Manual

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Part Number: Product

5620010 ARB REAR BAR

Description: Suited to

TOYOTA FJ CRUISER

vehicle/s:

WARNING

ALSO, NOTE THE FOLLOWING:

♦ This product is not suitable for fitment with Toyota tow bar. View page 3 for tow bar options. ♦ This product must be installed exactly as per these instructions using only the hardware supplied. ♦ In the event of damage to any rear bar component, contact your nearest authorised ARB stockist. ♦ Do not use this product for any vehicle make or model, other than those specified by ARB. ♦ Do not remove labels from this rear bar. ♦ 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: 13/3/07 Page 1 of 10 Fitting instructions# 3786375

FITTING REQUIREMENTS

REQUIRED TOOLS FOR FITMENT OF PRODUCT:

Basic Tool Kit

Jigsaw Allen Key

Hacksaw

HAVE AVAILABLE THESE SAFETY ITEMS WHEN FITTING PRODUCT:

17mm Socket

Air Hacksaw

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

M8 22Nm 16lbft M10 44Nm 32lbft M12 77Nm 57lbft

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Fitting Kit 6172202 PARTS LISTING

APPLICATION. PART NO. QTY DESCRIPTION

Mount Assembly To Chassis

Mount Trim to Bar

Mount Aluminium to bar

6151097 4581050 4581049 3757043 6821166 6151256 6151300 3199913 6151256 6151300 3199912

M12 x 50 x 1.25

12mm Spring Washer

12mm Flat washer

Recovery Hook

Reflector

M6 Button Head Cap Screw

M6 Cage nut

Trim Panel

M6 Button Head Cap Screw

M6 Cage nut

Aluminium Trim

Optional Accessories

Also available for the FJ Cruiser is an ARB Tow bar. This tow bar can only be fitted in conjunction with the ARB FJ Cruiser Rear Bar.

ARB FJ Cruiser Tow bar Part Number: 572 0010

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FITTING PROCEDURE

1. To fit the Rear Bar, the plastic bumper must be cut. This is done at a later stage.

2. Removing the plastic bumper from the vehicle.

4 top bolts

End screw to retain

Scrivet

2 underside bolts

There are 4 bolts along the top, 2 underneath the centre of the bar, 1 screw on the underside of each end, which must be retained, and a scrivet located on the passenger side of the vehicle in the door jamb which should also be retained.

Also undo the connectors for the parking sensors located in the lower corner of each end of the bar.

3. Once all fasteners have been removed, the bar can be pulled off the clips on each end by pressing down on the top edge whilst pulling the side out and back. Take care during this operation as the corners of the bar must be reused.

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Lift off foam

Remove bracket, left and right

Remove brackets from underside of body and from chassis. Also remove tow hook

4. Once the clips are undone, the bar can be removed. With the bar removed the support brackets, tow hook and foam can also be removed.

5. With the bumper removed from the car it can now be trimmed. First remove the silver end caps by releasing all (5) retaining clips. Then release the clips for the parking sensor wiring.

If the parking sensors are to be refitted, remove them from the bar by sliding the large plastic clip sideways and remove from bar.

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Measure 25mm down and scribe line 1 here

Line 4

Line 2

Line 3

Line 5

6. Marking the cut lines

Corner section cut line Images are of the left hand (drivers) side

First measure down 25mm from the rebate

and scribe a line (1) on the curved inner face.

Then run a line (2) down the corner of the

vertical face and the centre section of the bar, followed by a line (3) along the bottom as shown.

Place a ruler between the end points of the two lines and draw a line (4) as shown.

For the final line (5) join the top of line 2 and the start of line 1 as shown.

This line can be cut to remove the corner from the centre section

Line A

Square section cut line

Start by measuring 40mm from the edge and draw a line (A) down using a square.

Then but the ruler into the plastic whilst resting the top surface of the box section and mark on each side of the ruler at 20mm

Repeat this process this time placing the ruler between the two double ribs and marking each side of the ruler at 35mm out.

Join the first 2 marks with a line (B), and the second 2 marks with a line (C).

Line C Line B

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FITTING PROCEDURE

On the side of the box section measure a point 110mm from the end and square a line

110mm

Line D

Line F

70mm

(D) down. Turn the bar over to mark the cut lines

underneath. Place the ruler in the corner of the box section and mark at 110mm.

Draw a line (E) from this point to the end of line D

Place the ruler on the surface hard against the double rib and measure out 70mm

Draw a line (F) from this point to the end of line A

Finally draw a line (G) joining the end of line F

Line F

Line E

Line G

to the end of line E.

7. The final cut line viewed from underneath

8. The final cut line viewed from above.

The bar can now be cut using a hacksaw, air hacksaw and/or jigsaw, Taking particular care around the edge closest to the door as this will be seen when the bar is fitted.

Take care when cutting here

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9. Once the bumper has been cut, refit each corner to the vehicle by clipping it the top and side and refitting the screw to the underside. Refit the scrivet on the passenger side.

Pull rubber towards rear of vehicle

Push exhaust slightly towards front of vehicle until it is released from rubber mount as shown

10. Before fitting the rear bar, the exhaust mount must be released by pulling the rubber mount towards the rear of the vehicle and allowing the exhaust to drop slightly. This allows access to the bolt holes.

11. The tab found below the door opening in the centre of the car must be gently bent down to vertical with a hammer.

3 Cage nuts each side

12. Before the bar is fitted, the M6 cage nuts must be fitted to the outside 6 holes only. Fitting the cage nuts to the centre holes will be done once the bar is fitted.

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FITTING PROCEDURE

Passenger side Drivers side (with trimmed clip)

13. If parking sensors are to be fitted, insert them in the holes with the wiring pointing towards the outside of the bar as shown.

NOTE: the passenger side sensor clip will require trimming as shown below.

14. The rear bar can now be fitted. Carefully slide the rear bar over the chassis,

taking care not to damage the plastic bumper. This may require 2 people.

One person each side to lift bar into place

Large distance between bolts and end of plate to the bottom

15. With the bar sitting on the vehicle, place the recovery hook on with the large offset to the bottom, and attach to the front face using M12 x 50 x 1.25 bolts, 12mm flat washers and 12mm spring washers.

Do not fully tighten.

16. Take the chassis spacer and place between the chassis mount and the chassis of the vehicle. Attach using M12 x 50 x 1.25 bolts, 12mm flat washers and 12mm spring washers.

Check alignment of bar to vehicle, and then tighten all bolts to specified torque

Last Rev Date: 13/3/07 Page 9 of 10 Fitting instructions# 3786375

17. Fitting the cover trim and aluminium top

With the door open, fit the 4 M6 cage nuts to the centre holes of the rear bar, then place the cover trim in position and fit using M6 Button head cap screws. Then place the aluminium on top and fix using M6 Button head cap screws.

Fitting trim panel

Fitting Aluminum plate

Then place the aluminium on top and fix using M6 Button head cap screws.

Once fitted to the vehicle, peel the back off the reflectors and stick them to the outer wings of the bar as shown.

18. If re-fitting parking sensors, place the wiring loom over the chassis rails and plug into the socket at the bottom of each quarter panel. There is a black clip which can be pressed into a slot in the chassis to stop the wiring moving.

19. Finally refit the exhaust mount by hooking the exhaust into the hole in the rubber, and then

Push top and bottom equally

pushing the rubber mount towards the front of the vehicle without pushing the rubber off the black pins on the chassis.

Last Rev Date: 13/3/07 Page 10 of 10 Fitting instructions# 3786375

Last Rev Date: 13/3/07 Page 11 of 10 Fitting instructions# 3786375

ARB 5620010 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual