ARB 5650010 User Manual

TJ & TJ UNLIMITED JEEP REAR BAR & WHEEL CARRIER

• PART No 565 0010 REAR BAR.

• PART No 575 0012 WHEEL CARRIER.

• PART No 575 0020 TOW HITCH. (ACCESSORY)

• PART No 575 0030 HI-LIFT JACK ATTACHMENTS. (ACCESSORY)

• PART No 575 0040 WHEEL LOCKING NUTS – SET OF 4. (ACCESSORY)

•

PART No 575 0050 LICENCE PLATE LAMP RE-LOCATION KIT (ACCESSORY)

WARNING

NOTE 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 attempted.

♦ 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. ♦ 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: 16/10/2006 Page 1 of 25 3783210 - rev 3

GENERAL CARE AND MAINTENANCE

By choosing an ARB Bar, you have bought a product that is one of the most sought after 4WD products

in the world. Your bar is a properly engineered, reliable, quality accessory that represents excellent value. To keep your bar in original condition it is important to care and maintain it following these recommendations:

 Prior to exposure to the weather your bar should be treated to a Canuba based polish on all exposed

surfaces. It is recommended that this is performed on a six monthly basis or following exposure to salt, mud, sand or other contaminants.

 As part of any Pre Trip Preparation, or on an annual basis, it is recommended that a thorough visual

inspection of the bar is carried out, making sure that all bolts and other components are torqued to the correct specification. Also check that all wiring sheaths, connectors, and fittings are free of damage. Replace any components as necessary. This service can be performed by your local authorised ARB Stockist.

REQUIRED TOOLS FOR FITMENT OF PRODUCT:

METRIC SOCKET SET, METRIC RING AND OPEN ENDED SPANNER SET, PHILLIPS AND FLAT SCREW DRIVER SET, ELECTRIC DRILL AND METRIC DRILL BITS 6 mm, 13 mm AND 17 mm, LARGE HAMMER, CENTRE PUNCH, HEX KEY SET, PIN PUNCH, GREASE, METAL SCRIBE .

WIRE CUTTERS , SOLDERING IRON & SOLDER, INSULATING TAPE AND ELECTRICAL TERMINAL CRIMPERS ( IF RE-CONNECTING THE FACTORY HI LEVEL STOP LAMP ).

NOTE :- The bearings & seals for the wheel carrier are available as spare parts.

PART No QTY DESCRIPTION

732 0003 2 SEAL 732 0002 2 BEARING

HAVE AVAILABLE THESE SAFETY ITEMS WHEN FITTING PRODUCT:

Protective eyewear

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 9 Nm 4 lbft

Hearing protection

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

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USE PART No QTY DESCRIPTION

)

FITTING SLIDER TO

REAR STEP.

FITTING CATCH HOOK TO

REAR BAR.

FITTING BUMP STOP TO

REAR BAR.

FITTING GRABBER TO

REAR BAR.

PIVOT LOCKING BOLT 615 1222 1 BOLT LOCKING M8 x 50 mm LONG (FINE PITCH

INSTALLATION OF

COMPONENTS TO WHEEL

CARRIER.

REINFORCING BRACKET

FITMENT TO CHASSIS.

REINFORCING BRACKET

FITMENT TO CHASSIS

CONTINUED.

566 5677 1 SLIDER 682 1116 2 SQUARE PLASTIC PLUG

615 1283 2 SELF TAPPING SCREWS 459 0007 1 CATCH HOOK

615 1303 2 CAGE NUT M8 SHORT LEG 615 1022 2 BOLT M8 x 25 mm LONG 458 1046 2 SPRING WASHER M8 458 1044 2 FLAT WASHER M8

3756746 2 PACKER CATCH HOOK

584 8322 1 BUMP STOP 615 1312 2 M6 BUTTON HEAD CAP SCREW x 25 mm

615 1162 2 M6 NUT NYLOC 375 6677 1 GRABBER 615 1303 2 CAGE NUT M8 SHORT LEG 615 1022 2 BOLT M8 x 25 mm LONG 458 1046 2 SPRING WASHER M8 458 1063 2 PANEL WASHER M8

459 0011 1 CATCH ASSEMBLY 615 1263 4 SOCKET HEAD CAP SCREWS M8 x 20 mm LONG

458 1046 4 SPRING WASHERS M8 626 0002 1 STOPPER

458 1046 1 SPRING WASHER M8 458 1044 1 FLAT WASHER M8 615 1028 1 NUT M8

626 0001 1 GRABBER BUFFER 615 1331 2 CAP SCREW COUNTERSUNK M6 x 30 mm LONG

615 1162 2 NUT NYLOC M6 459 0001 1 GAS STRUT ASSY (inc 1 strut, 2 clips, 2 spheres)

615 1132 2 NUT FLANGED M8 458 1044 2 FLAT WASHER M8

459 0008 1 LOCKING PIN 459 0009 1 LOCKING PIN SPRING

459 0010 1 ROLL PIN

375 6886 R 1 BRACKET RIGHT HAND

375 6886 L 1 BRACKET LEFT HAND

615 1291 6 TAB BOLT M12 x 40 mm LONG FINE PITCH 458 1049 22 FLAT WASHER M12

458 1050 14 SPRING WASHER M12 615 1135 6 NUT M12 FINE PITCH 615 1250 2 BOLT M12 x 90 mm LONG COARSE PITCH 472 1570 2 DIA 17 mm CRUSH TUBE x 60 LONG 615 1255 4 BOLT M12 x 40 mm LONG COARSE PITCH 615 1189 8 NUT M12 COARSE PITCH

615 1340 2 BOLT M12 x 50 mm COARSE PITCH

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USE PART No QTY DESCRIPTION

BACKING PLATE TO

CHASSIS BEAM.

WHEEL CARRIER TO

REAR BAR.

MISC ITEMS TO REAR BAR

AND WHEEL CARRIER.

WHEEL MOUNTING PLATE

TO WHEEL CARRIER.

WHEEL MOUNTING PLATE

TO WHEEL CARRIER

PINNING BOLT .

HIGH LEVEL STOP LAMP TO

WHEEL CARRIER .

HIGH LEVEL STOP LAMP

WIRING LOOM EXTENSION

TO TAIL LAMP ON VEHICLE .

COVER PANEL FITMENT TO

REAR BAR.

319 9850 1 PLATE CHASSIS BEAM 615 1300 2 CAGE NUT M6

615 1017 2 BOLT M6 x 16 mm LONG 615 1046 2 FLAT WASHER M6 615 1042 2 SPRING WASHER M6 615 1306 2 CAGE NUT M12 SHORT LEG 615 1340 2 BOLT M12 x 50 mm 458 1049 2 FLAT WASHER M12 458 1050 2 SPRING WASHER M12

615 1330 1 NUT M20 NYLOC 615 1329 1 BOLT M20 x 190 mm LONG

636 4506 1 BUSH – ARM ASSY 625 0002 2 SPACER THIN – 9 mm THICK

180 302 4 CABLE TIES - BLACK

458 1299 5 WASHER FLAT NYLON

375 6909 1 WHEEL MOUNTING BRACKET

615 1382 3 WHEEL STUDS ½ “ WITH WHEEL NUT 615 1305 2 CAGE NUTS M12 LONG LEG 615 1355 2 BOLT M12 x 35 mm LONG 458 1007 2 PANEL WASHER M12 GOLD 458 1050 2 SPRING WASHER M12

615 1357 1 BOLT M10 x 30 mm LONG ( WITH WASHERS ) 458 1063 1 FLANGE NUT M10

615 1301 4 CAGE NUTS M8 LONG LEG 615 1234 4 BOLT M8 x 25 mm LONG BLACK 458 1047 4 SPRING WASHER M8 BLACK 458 1045 4 FLAT WASHER M8 BLACK

682 1195 1 REAR DOOR BLANKING GROMMET

6821194 1 TWIN CORE CABLE - 750 mm LONG

CR 07 1 CONVOLUTE TUBING - 7 mm x 750 mm LONG

320 104N 1 TAIL LAMP HOUSING WIRING GROMMET

666 005 1 RING TERMINAL 180 701 1 SCOTCH LOCK CONNECTOR 180 302 6 CABLE TIES - BLACK

455 8424 1 COVER PANEL 615 1300 4 CAGE NUT M6

615 1312 2 SOCKET HEAD CAP SCREW M6 x 25 mm LONG 615 1270 2 BOLT M6 x 40 mm LONG 615 1046 4 FLAT WASHER M6 458 1036 4 SPRING WASHER M6 584 8302 2 PACKER BLACK NYLON 625 0003 2 SPACER 8 mm THICK

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PREPARATION OF THE VEHICLE

LOCATION OF LOWER RUBBER STOPPER

1. REMOVAL OF THE FACTORY SPARE

WHEEL CARRIER. Remove the spare wheel from the vehicle. Unbolt the factory hi – level stop lamp and

disconnect the wiring loom. Remove the five bolts that hold the carrier

to the rear door – remove the carrier and replace the five bolts in their original positions and tighten. Fit a nylon washer under the head of each bolt.

Remove the rear bumper bar from the vehicle ( On Australian vehicles keep the licence plate lamp loom as it is re-used when fitting the optional licence plate lamp kit ) .

Remove the lower rubber tire stopper.

THE FOLLOWING COMPONENTS CAN BE INSTALLED ONTO THE

REAR BAR BEFORE IT IS FITTED TO THE VEHICLE.

CAGED NUTS

FOR INFILL

PANEL

M8 cage nuts

GRABBER

BRACKET

CATCH

HOO

SLIDER

PRE - ASSEMBLY OF REAR BAR

M6 cage nuts

2. INSTALLATION OF THE CAGE NUTS

Install four M8 cage nuts (short leg) from the back of the bar as shown. These cage nuts will be used to fasten the grabber bracket and the catch hook, as shown in the diagram above.

Install two M6 caged nuts in from the back of the bar as shown. These caged nuts will be used to fasten the infill panel.

BUMP

STOP

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PRE - ASSEMBLY OF REAR BAR

3. INSTALLATION OF THE SLIDER

Insert two plastic square plugs into holes in the rear bar. The plugs should snap into the square holes as shown.

Fasten the slider to the rear bar using the two black self-tapping screws provided.

NOTE: - Place the tapered face of the slider towards the front face of the rear bar as shown in the photo.

4. INSTALLATION OF THE CATCH HOOK

Fasten the catch hook to the rear bar as shown.

Use the M8 x 25 mm bolts, spring washers and panel washers supplied.

Make these bolts finger tight only at this stage.

They will be tightened after the wheel carrier has been adjusted.

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PRE - ASSEMBLY OF REAR BAR

Bump Stop

5. INSTALLATION OF THE BUMP STOP

Fasten the bump stop to the rear bar using two M6 x 25 mm stainless steel button head cap screws, flat washers and nyloc nuts. Place the washers and nyloc nut inside the right hand wing as shown.

NOTE: Do not over tighten.

M6 Lock Nuts

6. INSTALLATION OF THE GRABBER BOLTS.

Fit the two M8 x 25 bolts with, spring washers and flat washers to the bar as shown engaging only a few threads.

7. INSTALLATION OF GRABBER

Slide the grabber bracket over the bolts as shown in the photo.

Leave these bolts finger tight only at this stage. The grabber will require adjustment when the wheel carrier is fitted.

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PRE - ASSEMBLY OF REAR BAR

RH Wing Cavity

Adjusting Bolt

Pivot bracket

8. INSTALLATION OF PIVOT

ADJUSTING BOLT

Insert the M8 x 50 mm adjusting bolt (as shown in the photo) through the hole in the upright located in the right hand wing cavity.

There is a corresponding tapped hole in the pivot bracket that has been pre-drilled and threaded. Wind the bolt in until a few threads protrude through the bracket.

PRE - ASSEMBLY OF WHEEL CARRIER

THE FOLLOWING COMPONENTS CAN BE INSTALLED INTO THE WHEEL CARRIER BEFORE IT IS

FITTED TO THE REAR BAR .

NOTE :- THE BEARINGS AND SEALS ARE PRE - ASSEMBLED

ASSEMBLY , THESE PARTS ARE LISTED IN THE PARTS LIST .

INTO THE WHEEL CARRIER BUSH TO AID

STRUT SPHERE

LOCKING PIN

STOPPER

GRABBER

PRE - ASSEMBLY OF THE WHEEL CARRIER

1. INSTALLATION CATCH ASSEMBLY

Install the catch assembly using the four M8 x 20 mm socket head cap screws and spring washers provided and fully tighten.

NOTE:- The mounting plate has been pre tapped to accept the socket head cap screws.

Last Rev Date: 16/10/2006 Page 8 of 25 3783210 - rev 3

+ 17 hidden pages

ARB 5650010 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

WARNING

GENERAL CARE AND MAINTENANCE

NOTE :- The bearings & seals for the wheel carrier are available as spare parts.