ARB WINCH BULL BAR User Manual

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

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: +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

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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

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PARTS LISTING

APPLICATION. PART NO. QTY DESCRIPTION

Mount Assembly To Chassis

3756893

3756851R

3756851L

3193741

6151306

6151255

6151189

6151094

4581049

4581050

5846401

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

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

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

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

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

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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.

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FITTING PROCEDURE

7. Remove front bumper reinforcing bar.

NOTE: Retain the 8 x flange nuts removed for fitment of the bull bar chassis mount.

8. Remove front fasteners only from stone tray. Retain fasteners for reuse.

9. Using the 13mm drill bit and power drill, drill out the M8 captive nut located at the outboard side of the chassis as shown, on both sides of the vehicle.

10. Check that the nut body is completely removed, if it is not cleared, using a cold chisel and hammer chisel the remainder off.

FITTING PROCEDURE

Warning: Hammering and chiselling operations can result in flying metal debris, safety glasses should be worn.

Warning: Drilling operations can result in flying metal debris, safety glasses should be

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11. Fit an M12 cage nut to each of the captive nut plates 3193741.

12. Fit the chassis mount braces to the vehicle using the M12 x 30mm fine pitched bolt, M12 spring and flat washers supplied in the lower hole. Use an M12 flat washer as a spacer between the brace and the chassis at the upper hole and fix with an M12 x 40mm bolt M12 spring and flat washers and M12 x 1.75 nut. Do not tighten the bolts.

13. Insert the captive nut assembly through the front of the chassis and line it up with the hole at the end of the mount brace. Fix in place with the M12 x 1.75 x 40mm bolt, M12 flat and spring washers. Break off the end of the captive nut plate. Do not tighten yet.

14. Hold the 8mm spacer against the chassis mount brace forward facing surface and position the brace so that the spacers sit just below the surface of the chassis front face. Tighten the bolts.

FITTING PROCEDURE

Position brace so spacer won’t protrude from the chassis

Use a M12 flat washer as a spacer between chassis and bracket.

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15. Fit the chassis mount bracket to the chassis using the original flange nuts removed with the bumper reinforcing bar. Centre the chassis mount bracket and tighten.

CAUTION: When fitting the Chassis mounting bracket carefully bend the air-conditioning pipe out of the way.

16. If required, carefully bend piping clear of mount bracket assembly.

CAUTION: Piping must not rub on sharp edges, secure with cable tie and protective sheath if required.

17. Fix the chassis mount bracket to the chassis mount brace using M12 x 40mm bolts, M12 spring and flat washers, the 8mm spacers and M12 x 1.75 nuts. Tighten bolts

NOTE: If fitting winch continue through step 14, if

not skip to step 25

18. For ease of access the winch gearbox handle needs to be rotated. To do this undo all the cap screws, carefully lift the gearbox clear of the winch body so as not to damage the gasket. (Do not lift the gearbox more than a couple of millimetres) Rotate the gearbox anti-clockwise three hole spaces. Re-fit the caps-crews.

FITTING PROCEDURE

iew on gearbox end

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19. Using a 12mm drill bit, drill two new holes in the roller fairlead 25mm below the original holes.

Original hole.

New hole 25mm lower.

20. Remove the three screws from the control box and remove the cover.

21. Replace the two cables marked “A” and “F1” and replace them with the two cables (BLB560) supplied with the fitting kit. Label the cables the same as the original to assist in the wiring of the winch.

22. Place the winch on a table with the feet facing up and using an assistant; carefully lift the bull bar on top of the winch.

23. Attach the winch to the bull bar using two 1 ½” x 3/8” bolts from the winch fitting kit, 3/8” spring washer and 3/8” flat washers in the top holes.

24. Fit the 4 x M6 cage nuts from inside of the lower flange on the pan, where the stone tray will bolt up.

NOTE: Access to this area for cage nut fitment will be restricted once the RFL is fitted so it is important to insert these now.

25. Position the roller fairlead, and remove the circlips from the lower of the vertical rollers and push the pins up to give access to the lower bolts.

26. Fix the roller fairlead to the bar using the 1 ¾” x 3/8” bolts, spring and flat washers

FITTING PROCEDURE

Warning: Drilling operations can result in flying metal debris, safety glasses should be

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27. Fit the control box bracket to the bull bar using two M8 x 20mm bolts, M8 flat washers and M8 flange nuts.

28. Fit the control box to the control box bracket and connect the power cables to the winch as per the winch instructions.

29. Connect the ground wire to the tension bar of the winch.

CAUTION: Cable-tie all cables together and keep all cables clear of sharp edges and all moving parts.

30. Insert square grommets into holes in front of bar for licence plate fixing. Place the doublesided tape along the top edge of the number plate. Using supplied black screws, attach the licence plate to the bull bar.

NOTE: If winch is not fitted, licence plate can be located lower on bar front to cover RFL opening.

31. Fit the buffers to either side of the bull bar using 6 x M6 flange nuts. Do not over tighten.

FITTING PROCEDURE

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32. With the help of an assistant position the bull bar on the chassis bracket and fix with six M10 x 30mm bolts, M10 spring and flat washers.

CAUTION: Nip up bolts, but do not tighten

them yet.

33. Position the bull bar so that there is an even gap of approximately 20-25mm from the top face of the bar to the underside of the body edge. Then tighten all the bolts.

34. With the bull bar in position drill Dia10mm pinning holes, one though pilot hole in mount bracket and one through hole in upright for both sides of mounts.

35. Fix in place using two M10 x 30mm SEMS bolts, M10 Flat washers and M10 x 1.5 nuts per side.

36. Fit the bull bar stone tray by sliding the tray under the front of the vehicles original stone tray and fixing in place with the original bolts from the vehicles stone tray.

37. Fit the front of the stone tray to the bull bar with four M6 x 20mm bolts, M6 large panel washers and M6 spring washers.

FITTING PROCEDURE

Warning: Drilling operations can result in flying metal debris, safety glasses should be

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38. Replace 21W light bulbs for indicator (yellow reflector side) in supplied indicator/run lamp assemblies with 10W bulbs from fitting kit.

39. Assemble and install combination light surrounds (p/n 3163015) as per instructions no. 3786421 supplied with surround kit. Note: Optional fog lamps can be installed at this point as per fitting instruction no. 3783315 supplied with fog lamp kit 6821201

40. Wire up indicator and run lights using loom extensions supplied in fitting kit.

NOTE: The 4 Runner has a two wire circuit for indicators. The bull bar indicator and run lamps each side are to be wired to operate in parallel. ARB supplied wiring loom has Red and Green for power to indicator and run lamps – join these wires together. Other wiring detail supplied with accessories.

Toyota 4 Runner wiring colors:

RH White w/Black Stripe – Ground

Red w/Yellow stripe - Power

LH White w/Black Stripe – Ground

Red w/Green stripe - Power

FITTING PROCEDURE

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Last Rev Date: 11/05/2009 Page 12 of 13 Fitting instructions# 3786410

41. Take cut out trim from OE bumper (Step 4) and tuck leading edge of plastic trim under back edge of bumper and use OE retaining clips in the OE holes to hold bumper piece into place

42. Snap lower grille trim into place onto bumper piece.

FITTING PROCEDURE

43. Finished install of trim piece.

When finished make sure all bolts are tightened and that all wiring is clear of hot, sharp and moving parts.

Also supplied in the kit are two 3/8” rubber grommets and two 16mm plugs. The rubber grommets are for the two holes in the top pan if lights are being fitted. The two plastic plugs are for the holes in the top surface of the wings if no CB aerials are going to be connected.

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

i NOTE: Fog lamps shown fitted to bull bar below are optional accessories, ARB P#9249FCK

100mm 55WATT FOG LAMP KIT

ARB WINCH BULL BAR User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual