ARB 3434040 User manual

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If you have any queries regarding the installation of this product please contact the distributor from whom it was purchased, or alternatively the ARB office in your state.
Head Office – ARB Corporation Ltd VIC: 42-44 Garden Street, Kilsyth, Victoria, 3137 Tel: [phone] Fax: [phone]
WA:[phone] NSW: [phone] ACT: [phone] SA: [phone] QLD: [phone] NT: [phone] TAS: [phone]
ARB WINCH BULL BAR TO SUIT PAJERO GLS 1997 ON
No 3434040
WARNING
FOR VEHICLES EQUIPPED WITH SRS AIRBAG
WHEN INSTALLED IN ACCORDANCE WITH THESE INSTRUCTIONS, THE FRONT
PROTECTION BAR DOES NOT AFFECT OPERATION OF THE SRS AIRBAG.
TAKE NOTE OF THE FOLLOWING:
•THIS PRODUCT MUST BE INSTALLED EXACTLY AS PER THESE INSTRUCTIONS USING ONLY THE
HARDWARE SUPPLIED.
•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.
FITTING KIT No 6171268
USE PART No QTY DESCRIPTION
CONTROL BOX BRKT 3751357 1 CONTROL BOX BRACKET
TO B/BAR 6151021 2 BOLT M8 X 20mm
6151132
2 NUT FLANGE M8
4581044
2 WASHER FLAT M8
B/BAR TO CHASSIS 4581049 10 WASHER FLAT ½"
4581050
6 WASHER SPRING ½"
6151100
2 BOLT ½" X 1½"
6151138
6 NUT ½"
6151104
4 BOLT ½" X 4"
4581013
2 WASHER LOCATING
4581007
4 WASHER FLAT HD 13mm X 40mm
No PLATE BRACKET AND 3751584 1 NUMBER PLATE BRACKET
NUMBER PLATE 6151017 4 BOLT M6 X 16mm
4581035
4 WASHER FLAT M6
6151128
4 NUT FLANGE M6
ROLLER FAIRLEAD TO 6151110 2 BOLT 5/8" X 6"
B/BAR 6151140
2 NUT 5/8" NYLOC
4581051
4 WASHER FLAT 5/8"
WINCH TO B/BAR 6151073 4 BOLT UNC 3/8" X 1½"
4581048
4 SPRING WASHER 3/8
4581040
4 WASHER FLAT 3/8" X 1"
6821110
1 RUBBER GROMMET 56mm DIA
INDICATORS TO B/BAR 3500080 1 ARB INDICATOR KIT

TOOLS REQUIRED
Basic tool kit, drill and ½” drill bit
PROCEDURE
1. Place the bull bar onto a suitable stand.
2. Mount the control box to the control box bracket using the original nuts from the control box.
3. Assemble the number plate bracket to the bull bar using two M6.x 16mm bolts, flat washers and
flange nuts.
4. New mounting holes must be drilled in the roller fairlead in order to line up with the winch
mounting holes in the bull bar.
5. Remove the circlips which retain the side pins.
6. Remove the side pins and side rollers from the roller fairlead.
7. Position the roller fairlead hard up against the roller fairlead bracket on the bull bar.
8. From the rear of the bull bar, using the holes in the bull bar as a guide, mark out the new hole
position on the roller fairlead and drill out to ½”.
9. The winch clutch handle must be rotated to be easily accessible when fitted into the bull bar.
Remove all the Allen screws retaining the clutch and gearbox. Rotate this assembly clockwise by
72 degrees so the handle can be reached from the cut-out in the bull bar on the passenger side.
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NOTE: Take care not to lift the assembly more than a couple of millimetres while rotating to the
desired position to avoid unmeshing the gears.
10. Refit all bolts and tighten.
11. Fit the rubber grommet to the hole in the top of the bull bar.
12. Feed the control box cables down through the grommet to the winch motor.
13. Position the winch on the top of a 20 litre or 60 litre drum with the mounting holes facing upward.
14. Place the bull bar on top of the winch and align with the mounting holes. Using the bolts supplied
with the winch and the 3/8” washers in the ARB kit, fit and tighten the two upper bolts.
15. Place the roller fairlead in position over the two lower holes and fit two 3/8” x 1 ¾” bolts and 3/8”
washers supplied in the ARB kit. Finger tighten.
16. Ensure the winch and roller fairlead are aligned and tighten all bolts.
17. Using the 5/8” x 6” bolts supplied, place a flat washer under the head of both bolts and insert bolts
through roller fairlead bracket and side rollers. Fit the 5/8” nyloc nuts and tighten so that the rollers
turn freely.
18. Wire up the control box cable to the winch. Refer to the Warn winch manual for vehicle wiring
instructions.
19. Remove the existing bumper, number plate and the splash pan.
20. Lift the bull bar onto the front chassis rails and align the holes with the chassis.
21. Fit four of the ½” x 4” bolts, flat washers, spring washers and nuts through the bull bar and the
chassis. Loosely tighten them.
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22. Slide the 38mm x 4mm washer between the chassis and the bull bar mounting bracket. Position the
locating washer into the chassis eye. Refer to the diagram below for the correct bolt assembly.
Tighten all bolts making sure the bull bar is correctly aligned with the vehicle.
23. Assemble number plate onto the bull bar using the M6 x 16mm bolts, flat washers and flange nuts
from the bolt kit.
24. Fit the indicators to the bull bar and connect the indicator looms to the existing indicator loom with
the Scotchloks supplied. Test to ensure the indicators function correctly.
25. Refit the splash pan.
NOTE: Read the winch manual carefully before operating the winch.
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