ARB 3414470 Fitting Instructions Manual Download Page 17

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Last Rev Date: 07/11/12

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Fitting instructions# 3787907

FITTING BULL BAR

78.

Fit number plate to bar using 2 X M6 x
20 bolts, spring washers and standard
flat washers. (Winch version shown)

Wiring Schematic

Hilux 05 ON for fitment of ARB

commercial bull bar

Summary of Contents for 3414470

Page 1: ... 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 prod...

Page 2: ...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 authorized ARB Stockist FITTING REQUIREMENTS REQUIRED TOOLS FOR FITMENT OF PRODUCT 3 5 5 10mm drill bits and power drill Scissors or sharp knife 300mm Rule Tape measure Basic metric tool kit spanners a...

Page 3: ...ASSY L H S MOUNT BRACE R H S MOUNT BRACE L H S WASHER FLAT M10 OVERSIZED BOLT SEMS M10 NUT M10 X1 25P FINE THREAD NUT M10 X1 5P WASHER OFFSET 40 X 13 BOLT M10 x 30 x 1 5mm WASHER FLAT M10 X 25mm WASHER SPRING M10 BOLT M12 X 1 25 X 30 FINE THREAD WASHER SPRING M12 WASHER FLAT LG M12 X 4mm THK STONE TRAY 6522719 6151234 6151303 4581045 4581047 1 6 6 6 6 STONE TRAY BOLT M8 NUT CAGE M8 WASHER FLAT M8 ...

Page 4: ... to the outer corner of the bumper on the RHS as shown lining up the bumper to fender join wheel arch and headlamp lower edge Use masking tape to secure in position 4 Accurately mark cutting line using a marking pen 5 Repeat by reversing template for LHS 6 Accurately mark cutting line reference points at either end of the outer openings of the air intake as shown on the flat section don t measure ...

Page 5: ...level If you can get access to one use it once you have ensured the car is level If the cutting line appears to be crooked or uneven reapply the tape so it is straight NOTE If fog lamps are fitted disconnect them Check that there is nothing behind the bumper such as wiring in the cutting path before proceeding 9 Using the lower masked line as a guide accurately cut the bumper facia with an air hac...

Page 6: ...s brace and discard 13 Remove the lower bumper from the vehicle 14 Blow off all the plastic swarf then apply supplied pinch weld to the cut edge from wheel arch to wheel arch 15 If a flared vehicle then cut some short pieces of pinch weld to fit over the flaret edge as shown 16 If a flared vehicle drill a Dia 3 5mm hole about 15mm from the outer edge almost vertical through the rear wheel arch are...

Page 7: ... bumper on the RHS as shown lining up the bumper to fender join wheel arch and headlamp lower edge Use masking tape to secure in position 22 Accurately mark cutting line using a marking pen 23 Repeat by reversing template for LHS 24 Accurately mark cutting line reference points at either end of the outer openings of the air intake as shown on the flat section don t measure on the corner radius Not...

Page 8: ...evel If you can get access to one use it once you have ensured the car is level If the cutting line appears to be crooked or uneven reapply the tape so it is straight NOTE If fog lamps are fitted disconnect them Check that there is nothing behind the bumper such as wiring in the cutting path before proceeding 27 Using the lower masked line as a guide accurately cut the bumper facia with an air hac...

Page 9: ... brace and discard 31 Remove the lower bumper from the vehicle 32 Blow off all the plastic swarf then apply supplied pinch weld to the cut edge from wheel arch to wheel arch 33 If a flared vehicle then cut some short pieces of pinch weld to fit over the flaret edge as shown 34 If a flared vehicle drill a Dia 3 5mm hole about 15mm from the outer edge almost vertical through the rear wheel arch area...

Page 10: ...ll wires will reach the appropriate connections 39 Starting with the passenger side use scotch locks to connect the red wire from the indicator loom 6821152 to the green wire from the vehicles front park lamp 40 Connect the Yellow Black wire from the relay loom to the Green Black wire from the vehicles left indicator 41 Connect the Yellow and Black wires from the relay loom to the Green and Black ...

Page 11: ... VEHICLE PREPARATION 44 Find a suitable place and mount the relay NOTE Always mount the relay upright to help prevent water ingress 45 Run the main black wire to a suitable earth 46 Connect the main power wire red to the positive terminal of the battery Main battery if a dual battery system is installed 47 Using the cable ties supplied secure the loom keeping clear of any hot sharp or moving surfa...

Page 12: ... lamps and replace these with the four screws provided in the kit Push the square plastic plugs into the holes on the turn signal bracket Fasten the turn signal lamps to the bull bar as shown NOTE The drain holes in the lamp are at the bottom As shown IMPORTANT The turn signal amber section is to face to the inside of the bull bar IF FITTING A WINCH 51 To fit an 8 9000lb or 9 5XP winch rotate gear...

Page 13: ...box bracket to the control box then thread the cables through the aperture cut into the top of the pan 57 Mount the control box bracket onto the top pan using M8 bolts flat washers and flanged nuts Use the cable ties to ensure the winch cables are secure clear of moving parts and sharp edges and tie them together 58 Place winch on a stand with mounting holes facing upwards and lower bull bar onto ...

Page 14: ...e adjacent picture 61 Fit roller fairlead into cutout and refit bolts and tighten firmly Note For ease of tightening lower bolts use a stepped ring spanner 62 Connect the winch control box cables to the winch Refer to Warn installation instruction manual when wiring up winch 63 Ensure that all cables are installed well clear of all sharp or moving parts by using cables ties from bolt kit 64 Cable ...

Page 15: ...and std pitch nut at rear Fasten upper position with M10 SEMS bolt flat washer and nut at rear 67 Bolt the bracket to the chassis using M12 x 1 25 x 30 fine pitch bolt with the large M12 x 4 thick flat washer and spring washer 68 Repeat on other side 69 Set the distance between the inner mount faces at 785mm 70 Position the bar on the vehicle and fasten it to the impact absorber brackets using the...

Page 16: ... 73 Drill 1 hole per side and secure using the M10 x 30 SEMS bolts and flange nut 74 Fit the centre stone guard as shown using M8 black bolts black M8 flat washers black M8 spring washers cage nuts 75 Cable tie the plastic wheel liner on the LH and RH side of the vehicle to the hole provided in the wing 76 If fitting wing under panels proceed now Separate fitting instructions are included with sup...

Page 17: ...d All rights reserved this document must not be reproduced without the express authority of ARB Corporation Ltd FITTING BULL BAR 78 Fit number plate to bar using 2 X M6 x 20 bolts spring washers and standard flat washers Winch version shown Wiring Schematic Hilux 05 ON for fitment of ARB commercial bull bar ...

Page 18: ... the express authority of ARB Corporation Ltd ONCE BAR IS FITTED Ensure all bolts are tensioned correctly All wiring is clear of sharp edges or moving surfaces and secured properly Piping is secured well away from sharp or moving components Check operation of winch if fitted Check all wiring and connections to turn signal lamps etc are functioning correctly FITTED PRODUCT ...

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