ARB WINCH BULL BAR User Manual

Last Rev Date: 11/05/2009 Page 1 of 13 Fitting instructions# 3786410

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:

3421500 / 3421510

Fitting kit No:

6172348

Product
Description:

ARB WINCH BULL BAR

Suited to
vehicle/s:

TOYOTA 4 RUNNER YEAR MODELS 03 ON

WARNING

REGARDING VEHICLES EQUIPPED WITH SRS AIRBAG:

When installed in accordance with these instructions, the front protection bar does not affect operation of
the SRS airbag.

ALSO, NOTE THE FOLLOWING:

i This product must be installed exactly as per these instructions using only the hardware supplied.

i 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.

i Do not use this product for any vehicle make or model, other than those specified by ARB.

i Do not remove labels from this bull bar.

i This product or its fixing must not be modified in any way.

i The installation of this product may require the use of specialized tools and/or techniques

i It is recommended that this product is only installed by trained personnel

i 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

i During installation, it is the duty of the installer to check correct operation/clearances of all

components

i Work safely at all times

i Unless otherwise instructed, tighten fasteners to specified torque

ARB 4x4 ACCESSORIES

Corporate Head Office

42-44 Garden St Tel: [phone]
Kilsyth, Victoria Fax: [phone]
AUSTRALIA 3137

Australian enquiries [e-mail]
North & South American enquiries [e-mail]
Other international enquiries [e-mail]

www.arb.com.au

Last Rev Date: 11/05/2009 Page 2 of 13 Fitting instructions# 3786410

Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd

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.

FITTING REQUIREMENTS

REQUIRED TOOLS FOR FITMENT OF PRODUCT:

Metric socket and spanner sets 8-25mm range External Circlip pliers

Screwdrivers Philips and Flat blade Cold chisel

Hammer

Power Drill 13mm capacity 10mm and 13mm drill bits

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

M8 22Nm 16lbft

M10 44Nm 32lbft

M12 77Nm 57lbft

OPTIONAL LIGHT SETS TO SUIT THIS PRODUCT:

i ARB 6821201 FOG LAMP SUIT 3163015

i Up to IPF 900 SERIES FOG OR DRIVING LIGHT SETS

Last Rev Date: 11/05/2009 Page 3 of 13 Fitting instructions# 3786410

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

Mount Assembly To Chassis

3756893

3756851R

3756851L

3193741

6151306

6151255

6151189

6151094

4581049

4581050

5846401

1

1

1

2

2

8

6

2

18

10

4

Bracket Mount Assembly

Bracket Mount Brace RHS

Bracket Mount Brace LHS

Captive Nut Plate

Nut Cage M12 x 1.75

Bolt M12 x 1.75 x 40mm

Nut M12 x 1.75

Bolt M12 x 1.25 x 30mm

Washer Flat M12

Washer Spring M12

Spacer 8mm

Bull Bar To Mount Bracket Assy

6151357

4581040

6151026

10

10

10

SEMS Bolt M10 x 1.5 x 30mm

Washer Flat M10 x 2mm

Nut M10 x 1.5

Stone Tray to Bull Bar

6542091

6151300

6151213

4581084

4581287

1

4

4

4

4

Stone Tray

Nut Cage 6mm

Bolt M6 x 20mm

Washer Flat M6

Washer Spring M6

Indicators To Bull Bar

3163015
6821152

180701

6821192

6821151R

6821151L

1
2
6
2
1
1

Combination Light Surround Kit
Turn signal / clearance light loom
Scotch lock
Bulb 12V 10W BA15S
Turn Signal / Clearance Light
Turn Signal / Clearance Light

Winch To Bull Bar

EG50

3756499

6151021

4581044

6151132

BLB560

4581040

6151074

1

1

2

2

2

2

4

2

Rubber Grommet

Bracket Control Box

Bolt M8 x 20mm

Washer Flat M8

Nut Flange M8

Cable Black 560mm

Washer Flat M10 x 2

Bolt 1 ¾” x 3/8” UNC

Buffers to Bull Bar

3162470R

3162470L

6151128

1
1

12

Buffer
Buffer
Nut M6 Flanged

Number Plate To Bull Bar

6821189
6151384
6781408

2
2
1

Grommet Nylon Nut
Screw
Tape Double sided

Miscellaneous

6821132

180302

3162152

2
8
2

Rubber Grommet 3/8” ID
Cable Ties
Plastic Plug 16mm DIA

Last Rev Date: 11/05/2009 Page 4 of 13 Fitting instructions# 3786410

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. Undo bumper light electrical connections and
then remove front bumper cover from vehicle

NOTE: For 03-05 Models only, follow steps 2 to
4 and 44 to 46 regarding plastic trim support.

2. Remove plastic support from inside OE
bumper cover.

3. With trim piece fitted to OE bumper cover as
shown, mark out and draw a line 25mm (1”)
from the leading edge of the lower grille trim
approx. 864mm (34”) long

4. Remove trim and then cut out plastic panel
along marked line from OE bumper facia, set
this piece aside for fitting later.

5. Remove trim piece and support bracket

6. With trim piece removed, mask the area
around the headlight and the front guard and
paint the lower section under the front guard
black.

Paint this
area black
with trim
removed.