ARB 3414470 User manual

Last Rev Date: 07/11/12
Page 1 of 18
Fitting instructions# 3787907
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:
3414470 F/ Kit 6173258, Winch F/Kit 3514010
Product Desc:
HILUX ARB COMMERCIAL BULL BAR 2005 ONWARDS
INCLUDING 2011 UPDATE.
Suited to
vehicle/s:
4 x 4 Flared and Non Flared (SRS AIR BAG MODELS)
Not suitable for 2WD (4 x 2) models
NOTE: Optional winch kit 3514010
Optional wing underpanel kit 3514070
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:
♦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: [phone]
Kilsyth, Victoria Fax: [phone]
AUSTRALIA 3137
Australian enquiries [email protected]om.au
North & South American enquiries [e-mail]
Other international enquiries [e-mail]
www.arb.com.au

Last Rev Date: 07/11/12
Page 2 of 18
Fitting instructions# 3787907
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
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 and sockets
Stepped ring spanner to suit 3/8” bolt
25 and 50mm masking tape
Air hacksaw or jigsaw
Screwdrivers Philips and blade type
Fine point permanent marking pen
Fine flat file or sand paper and sanding block
Side cutters
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
7lbft
M8
22Nm
16lbft
M10
44Nm
32lbft
M12
77Nm
57lbft
Winches that are recommended for this product; WARN 8000lb XD, 9000lb XD, 9.5XP, 9000XDC

Last Rev Date: 07/11/12
Page 3 of 18
Fitting instructions# 3787907
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
**CONTROL BOX FITMENT
(SUPPLIMENTARY KIT )
3756499
6151234
4581045
6151132
EG50
180302
1
2
2
2
2
8
CONTROL BOX BRACKET
BOLT M8 x 25 LONG (BLACK)
WASHER FLAT M8 (BLACK)
NUT FLANGE M8
GROMMET RUBBER
CABLE TIES
**WINCH MOUNT
(SUPPLIMENTARY KIT)
4581040
6151074
BLB850
4
2
3
WASHER FLAT 3/8”
BOLT UNC 3/8” x 1 ¾”
CABLE BLACK 850mm
BOLT BULL BAR TO MOUNTS
6151428
6151355
4581049
4581064
6
6
6
6
NUT FLANGE M12
BOLT M12
WASHER FLAT M12
WASHER SPRING M12
BULL BAR PINNING
6151357
6151321
2
2
BOLT (SEMS) M10
NUT FLANGE M10
IMP. ABS. TO CHASSIS
3757766R
3757766L
3194068R
3194068L
4581288
6151357
6151133
6151026
4581008
6151232
4581040
4581048
6151095
4581064
4581007
1
1
1
1
4
2
4
4
2
2
4
6
2
2
2
MOUNT BRACKET ASSY R.H.S
MOUNT BRACKET 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
WASHER SPRING M8
INDICATORS TO BULL BAR
6821151R
1
INDICATOR KIT, RHS
6821151L
1
INDICATOR KIT, LHS
6821116
4
NYLON PLUG
6151308
4
SCREW, SELF TAPPING
6821152
2
WIRING LOOM
6821198
1
INDICATOR RELAY LOOM
1080302
6
CABLE TIES
NUMBER PLATE
6151017
6151300
4581072
4581036
2
2
2
2
BOLT M6
NUT CAGE M6
WASHER FLAT M6
WASHER SPRING M6
MISCELLANEOUS
6191026
3787817
3787818
3787979
3787980
6151338
1
1
1
1
1
2
PINCH WELD @ 2700MM
CUTTING TEMPLATE NON FLARED 05-11
CUTTING TEMPLATE FLARED 05-11
CUTTING TEMPLATE FLARED 11on
CUTTING TEMPLATE NON FLARED 11on
SCREW PAN HD PLASTITE
**NOTE: GREY FILLED ITEMS LISTED ARE AVAILABLE ONLY IN SUPPLIMENTARY WINCH FITTING KIT
3514010, THEY DO NOT COME IN STANDARD KIT.
NOTE IF FITTING AN XDC WINCH, SUPPLIMENTARY KIT 3500140 CONTROL BOX BRACKET IS REQUIRED

Last Rev Date: 07/11/12
Page 4 of 18
Fitting instructions# 3787907
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
VEHICLE PREPARATION 2005 -2011 VEHICLES (FOR 2011 ON VEHCILES
GO TO STEP 19)
BUMPER CUT
1. Cut out the relative supplied bumper
cutting template to suit the bumper type
– flared or non flared.
2. Flared bumpers have a flaret attached,
leave this on the bumper on for marking
and cutting
3. Carefully and accurately apply the
cutting template 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 on the
corner radius)
Note: Masking tape shown for reference
7. Accurately measure and mark at the
center of the bumper facia up at two
points on either end of the number plate
boss top face as shown.
Note: Masking tape shown for reference
Measure up
and mark
at198mm
(lower edge of
masking tape)
Measure and
mark at 158mm
(lower edge of
masking tape)
158
198

Last Rev Date: 07/11/12
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Fitting instructions# 3787907
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
VEHICLE PREPARATION 2005 -2011 VEHICLES
8. As accurately as possible, using 50mm
masking tape, place the bottom edge of
the tape along the marks for the cutting
edge right across the bumper and
flarets.
NOTE: This is intended to be a straight
horizontal cut across the bumper. A laser
level is the optimum way to ensure the cut
is 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 hacksaw or jig saw or similar
(always use eye and ear protection).
NOTE: You may need to use a hand
saw to cut through the bumper
behind flaret on the flared bumper
version as shown.Ensure the saw is
horizontal.
Warning: Drilling operations can result in flying
metal debris, safety glasses should be worn.
Align lower tape edge accurately to
marked line

Last Rev Date: 07/11/12
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Fitting instructions# 3787907
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
VEHICLE PREPARATION 2005 -2011 VEHICLES
10. Deburr the cut edge with a fine flat file
or sandpaper and block
11. Remove the lower bumper braces and
discard.
12. Remove the chassis cross-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 area of the flaret and then into the
mud guard flare as shown
17. Drill a Dia 5.0mm clearance hole in the
rear piece of the flaret only
18. Fit a plastite screw to secure the rear of
the flaret as shown

Last Rev Date: 07/11/12
Page 7 of 18
Fitting instructions# 3787907
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
VEHICLE PREPARATION 2011 ON VEHICLES
BUMPER CUT
19. Cut out the relative supplied bumper
cutting template to suit the bumper type
– flared or non-flared.
20. Flared bumpers have a flaret attached,
leave this on the bumper on for marking
and cutting
21. Carefully and accurately apply the
cutting template 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.
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)
Note: Masking tape shown for reference
25. Accurately measure and mark at two
points on either end of the number plate
boss top face as shown.
Note: Masking tape shown for reference
Measure up
and mark at
90mm from the
top ceiling of
the lower grille
aperture.
Measure and mark
10mm from the top
of the raised
number plate boss
of the bumper.
10mm
90mm

Last Rev Date: 07/11/12
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Fitting instructions# 3787907
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
VEHICLE PREPARATION 2011 ON VEHICLES
26. As accurately as possible, using 50mm
masking tape, place the bottom edge of
the tape along the marks for the cutting
edge right across the bumper and
flarets.
NOTE: This is intended to be a straight
horizontal cut across the bumper. A laser
level is the optimum way to ensure the cut
is 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
27. Using the lower masked line as a guide
accurately cut the bumper facia with an
air hacksaw or jig saw or similar (always
use eye and ear protection).
NOTE: You may need to use a hand
saw to cut through the bumper
behind flaret on the flared bumper
version as shown.Ensure the saw is
horizontal.
Warning: Drilling operations can result in flying
metal debris, safety glasses should be worn.
Align lower tape edge accurately to
marked line

Last Rev Date: 07/11/12
Page 9 of 18
Fitting instructions# 3787907
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
VEHICLE PREPARATION 2011 ON VEHICLES
28. Deburr the cut edge with a fine flat file
or sandpaper and block
29. Remove the lower bumper braces and
discard.
30. Remove the chassis cross-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 of the flaret and then into the
mud guard flare as shown
35. Drill a Dia 5.0mm clearance hole in the
rear piece of the flaret only
36. Fit a plastite screw to secure the rear of
the flaret as shown

Last Rev Date: 07/11/12
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Fitting instructions# 3787907
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
VEHICLE PREPARATION ALL VEHCILES
WIRING OF LIGHTS
37. Carefully read the wiring diagram
supplied at the end of these
instructions.
38. Take the relay loom (6821198) from the
kit and position in the engine bay so
that all 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 wires from the indicator loom.
42. Let the indicator loom hang freely for
connecting to the bull bar indicators
later on.
43. Do the same for the driver’s side, using
the wiring diagram supplied as a
reference to the correct wire colours.

Last Rev Date: 07/11/12
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Fitting instructions# 3787907
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
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 surfaces.
CABLE TIE
LOOM

Last Rev Date: 07/11/12
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Fitting instructions# 3787907
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
BULL BAR PREPARATION
48. Working within the bull bar, insert 2 x
M6 caged nuts to inside front face of
top pan.
NOTE: Caged portion faces the rear of the
bar.
49. Fit 4 x M8 cage nuts across inside of
lower pan as shown
50. Remove the fastening screws and nuts
supplied with the turn signal/clearance
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 gearbox 72° counter clockwise.
52. Stand winch upright and undo the
capped head screws and by lifting the
gearbox only a couple of millimetres,
rotate the gearbox. Once in position,
refit all screws and tighten firmly.
WARNING: Do not lift gearbox more than a
couple of millimetres.
ORIGINAL
VIEWED FROM
LHS OF VEHICLE
ROTATED

Last Rev Date: 07/11/12
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Fitting instructions# 3787907
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
BULL BAR PREPARATION
53. Remove the cover from the control box.
54. Replace the three main power cables
that go from winch to control box. Make
sure that you identify the colour codes
on the new cables before closing
control box cover.
55. This must be done for whatever winch
is to be fitted to the bull bar.
56.
Bolt the control 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 winch. Align all four holes, using
the original 3/8” bolts that came with the
winch in the top two holes and the
longer 1 ¾” x 3/8” bolts, supplied in the
kit, in the lower two holes plus 3/8”
spring and flat washers with each bolt.
59. When all bolts are fitted and finger tight,
tighten top holes only, using a stepped
ring spanner and remove lower bolts.

Last Rev Date: 07/11/12
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Fitting instructions# 3787907
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
BULL BAR PREPARATION
60. Drill two new 13mm holes in the roller
fairlead provided in the kit, as shown on
the 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 tie main cables that go to battery
in between underside of bar and brace.
Refer to photo to see where to cable tie
to bull bar.

Last Rev Date: 07/11/12
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Fitting instructions# 3787907
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
FITTING BULLBAR
65. Loosely bolt the impact absorbers to the
chassis using the factory studs with the
large M10 flat washers, spring washers
and M10 x 1.25 fine pitch nuts.
66. Loosely bolt the chassis tension bracket
to the impact absorber at the lower
position using an M10 bolt, offset
washer at front, std flat washer, spring
washer 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 M12 bolts, washers,
spring washers and flange nuts
provided.
71. Adjust the bull bar position up/down and
in/out to achieve uniform gaps between
the bar and the fenders on each side of
the vehicle. The optimal clearance
between the bull-bar and the cut edge
of bumper fenders is 15 -20mm.
Tighten the impact absorber and bull bar
bolts to specified torque.

Last Rev Date: 07/11/12
Page 16 of 18
Fitting instructions# 3787907
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd
FITTING BULL BAR
72. Once satisfied with the position of the
bull-bar, using a 10mm drill, drill
through the 10mm holes in the impact
absorber
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 supplementary kit
3514050.
77. Carefully cut the lower part of the
plastic wheel liner that hangs below the
wing stone guard with a pair of scissors
or sharp knife.

Last Rev Date: 07/11/12
Page 17 of 18
Fitting instructions# 3787907
Copyright © 2005 by ARB Corporation Limited. 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

Last Rev Date: 07/11/12
Page 18 of 18
Fitting instructions# 3787907
Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without 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