ARB DELUXE BULL BAR 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 DELUXE BULL BAR TO SUIT
MAZDA BRAVO & FORD COURIER 1999 On
Part No’s 32/3440050 without flares, Part No’s 32/3440060 with flares
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.

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BULL BAR FITTING KIT No 6171778/79
USE PART No QTY DESCRIPTION
IMPACT ABSORBER TO CHASSIS 3751785L 1 IMPACT ABSORBER LHS
3751785R
1 IMPACT ABSORBER RHS
6151098
4 BOLT M12 X 1.5 X 40mm
4581049
4 WASHER 12mm
4581050
4 WASHER SPRING 12MM
BRACE TO BULL BAR 4681123L 1 BRACE COURIER/MAZDA
4681123R
1 BRACE COURIER/MAZDA
BULL BAR TO IMPACT ABSORBERS 6151232 6 M10 X 30mm BOLT
4581040
6 M10 FLAT WASHER
4581048
6 M10 SPRING WASHER
NUMBER PLATE TO BULL BAR 6151017 2 M6 x 16mm BOLT
6151128
2 M6 FLANGE NUT
6151046
2 M6 FLAT WASHER
STONE TRAY BULL BAR 3314481 1 STONE TRAY
6151021
7 M8 X 20mm BOLT
6151132
7 M8 FLANGE NUT
4581044
7 M8 FLAT WASHER
3500200
6151132 1
4 BUFFER
M8 FLANGE NUT
3500080
1 ARB INDICATOR KIT (CONTAINS LEFT AND RIGHT)
FOR THE WINCH BULL BARS ONLY
USE PART No QTY DESCRIPTION
8-9000lb WINCH 4581040 4 M10 FLAT WASHER
NUMBER PLATE 3751789 1 NUMBER PLATE BRACKET
6151017
4 M6 X 16 BOLT
6151128
4 M6 FLANGE NUT
4581035
4 M6 FLAT WASHER
CONTROL BOX BRACKET 3751564 1 CONTROL BOX BRACKET
TO BULL BAR 6151021 2 M8 X 20mm BOLT
6151132
2 M8 FLANGE NUT
6151046
2 M8 FLAT WASHER
6821110
1 GROMMET
180302
6 CABLE TIE
BLB560
2 BATTERY LEAD BLACK
BLR560
1 BATTERY LEAD RED
TOOLS REQUIRED
Basic tool kit, long socket extension, drill and 10mm drill bits.

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FITTING PROCEDURE
1. Remove bumper bar and tow hooks from the vehicle.
2. Fit the left and right hand impact absorbers to the top of the chassis rails using the M12 bolts, spring washers and
flat washers supplied. Finger tighten only. (Refer to diagram 1)
DIAGRAM 1
ACCESS TO TOP BOLTS IS VIA
THE ENGINE COMPARTMENT
FRONT RETAINING
BOLT
BULL BAR
MOUNTING HOLE
BULL BAR
MOUNTING HOLES
3. Measure the distance between the outside edges of the impact absorbers and set them at 815mm apart then tighten
the two top bolts retaining the impact absorber to the chassis.
4. Tighten the remaining front impact absorber bolts. This allows self-aligning of the impact absorbers to the
mounting points on the bull bar.
5. Attach the bull bar braces to the vehicle where the tow hooks were removed using the original bolts but do not
tighten. (Refer to diagram 2)
DIAGRAM 2
ATTACH BRACES USING ORIGINAL BOLTS
TO TOW HOOK MOUNTING POSITION
6. Fit the turn signal indicators supplied into the bull bar. NOTE: Refer to the instructions supplied with the turn
signal indicator kit.
7. Attach the number plate to the front of the bull bar using the two M6 x 16mm bolts, flat washers and flange nuts
supplied. (The winch bull bar requires the fitment of a bracket (supplied) to raise the number plate clear of the
roller fairlead.)
8. Fit the rubber buffers supplied to the bull bar using the M8 flange nuts supplied in the fitting kit.

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9. WINCH BARS: FITTING THE 8000 OR 9,000lb WINCH
A. Remove the cover of the control box, disconnect the two heavy short black cables and the heavy short red
cable and replace with the corresponding cables supplied. Replace the cover; fit the control box to the control
box bracket using the two 1/4” nuts, washers and spring washers. Then bolt the control box bracket to the bull
bar using the M8 x 20mm bolts, flat washers and flange nuts supplied. Refer to Diagram 3.
DIAGRAM 3
Control box
bracket
B. To place the winch clutch handle in a convenient location, the winch gearbox must be rotated 1 hole space, 72
degrees, in a clockwise direction when viewed from the gearbox end. Place the winch on its end and remove
all gearbox bolts. Gently raise the gearbox just enough to rotate it. Do not completely remove the gearbox and
avoid damaging the gasket. Refit all bolts and tighten. Refer to Diagram 4A.
DIAGRAM 4A DIAGRAM 4B
C. To place the winch motor in the correct location, the winch motor must be rotated 90 degrees, in an anti
clockwise direction when viewed from the motor end. Place the winch on its end and remove the 2 motor
retaining bolts. Gently raise the motor just enough to rotate it. Do not completely remove the motor and avoid
damaging the gasket. Refit all bolts and tighten. Refer to Diagram 4B.
D. Drill the roller fairlead as shown in Diagram 5 then assemble into the front of the bull bar. Lift the winch into
place and using the 3/8” washers supplied in the fitting kit and the bolts and spring washers supplied with the
winch, bolt securely into position. NOTE: The gearbox is on the LHS. The winch cable spools from the
bottom.

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DIAGRAM 5
25.0m
m
Ori
g
inal hole
N
ew hole
BULL BAR TO VEHICLE FITMENT:
9. Lift the bull bar onto the impact absorbers with the braces on the outside of the bull bar and loosely bolt in place
using the M10 x 30mm bolts, washers and spring washers. (Refer to Diagram 6).
DIAGRAM 6
Two bolts on the outside
and one on the inside.
Brace is bolted on the
outside of the mount.
10. Adjust the bull bar until a uniform gap is achieved to the mudguards and grill. Securely tighten all bolts.
11. Fit the stone tray to the vehicle using seven M8 x20mm bolts, M8 flat washers and M8 flange nuts. (Refer to
diagram 7)
Diagram 7
Two bolts in
either side Three bolts along the front

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12. Connect the bull bar turn signal indicator looms to the existing turn signal indicator loom with the Scotchloks
supplied and test to ensure they function correctly.
13. Using a pair of tin snips, trim back the plastic inner guard and metal panel that sit below the line of the bull bar.
(Refer to diagram 8)
DIAGRAM 8
13. WINCH BARS ONLY: Wire the winch in accordance with the Warn fitting instructions, taking care not to route
the cables over sharp edges, hot surfaces or near moving objects. Secure the cables to the vehicle using the cable
ties supplied.