Dobinsons BU59-3660 & BU59-3510 User manual

Dobinsons Springs and Suspension www.dobinsonsprings.com
Bullbar Installation Guide
Part Number: BU59-3660 & BU59-3510
Fits:
Toyota Hilux Vigo 2005 - 2011
This Bullbar will take approximately 3 hours to install
Tools required are
•Spanners and socket set.
•Pneumatic hacksaw.
•Screwdrivers
•Pliers and side cutters
Dobinsons BULLBARS should be installed by a qualified installer and it is
the installer responsibility to ensure correct fitment.
Fully read and understand the instructions before beginning the installation

Dobinsons Springs and Suspension www.dobinsonsprings.com

Dobinsons Springs and Suspension www.dobinsonsprings.com

Dobinsons Springs and Suspension www.dobinsonsprings.com

Dobinsons Springs and Suspension www.dobinsonsprings.com

Dobinsons Springs and Suspension www.dobinsonsprings.com
Fitting Guide
1. Remove the number plate.
2. Remove the grill by removing the screws and
clips in the top and then un-clipping the lower
section from the bumper.
3. Remove the bumper by removing the 2 clips
at the top in the centre, the 4 bolts on the
support mounds that mount to the cross
member, the 6 bolts underneath, and the 2
bolts in the wheel arch.
4. Then pull away the wheel arch splash guard
and right at the very back at the top there is
another clip that can be removed on each
side. Unclip the fog light wiring loom from
each side and remove the bumper.
5. Remove the bumper support by removing the
4 nuts, and the 2 clips on each side that attach
it to the bottom splash guards.
6. Remove the plastic shrouds from between the
headlights and the radiator face.
7. Remove the headlights there are 3 screws on
the top and one bolt on the side.
8. Remove the original bump support mounts by
removing the 3 screws at the back of each.
9. While the headlights are out it is now a good
time to run the wiring for the new parker
lights and indicators.
10. Wire up the lights. Using a multimeter or test
light first locate the earth wire, parker positive
and indicator positive wires from the wiring
on the back of the original vehicle lights on
each side. This is easiest done by reaching in
behind the wheel arch liner and unclipping
both lights plugs for easier access.
11. Unclip the wiring from the indicator/parker
lights. Check that the wiring will be long

Dobinsons Springs and Suspension www.dobinsonsprings.com
enough to reach the new bullbar
indicator/parker lights and extend if required.
Using the diagram at the end of this manual,
join the corresponding wires to original
vehicle wires located in the previous step. The
wires can be joined by either using good
quality snap lock crimp connectors or by
soldering. Ensure the connection is secure and
is sufficiently insulated.
12. While the head lights are out, remove the
original side bumper mounts. These are the
long black sections that support the bumper
near the wheel arch. Do this by removing the
bolt on the side, and then from inside the
guard unclip both clips to free the bracket..
13. Re-install both head lights once the wiring is
run and the bumper clips have been removed.
14. Fit the bulbar bracket to the chassis with the
hardware supplied as per the diagrams on
page 3 and 5 (there are 2 styles of brackets
used.. Ensure when tightening that the
bracket is central to the vehicle.
15. Carefully un-wrap the bulbar taking care not
to scratch it especially on the top loops.
R
e
i
n
s
tall the number plate. If installing driving
lights to the bullbar it is easiest to install now.
16. If not installing a winch skip to step 24.
17. See the Installation section of your Dobinsons
4x4 Winch manual for specific detailed fitting
instructions. For a brief overview see the
following steps.
18. Test fit your winch to the mounting bracket
and do up loosely with the clutch handle on
the left hand side of the vehicle.
19. This may require the clutch handle and gear-
box housing to be rotated forward one or 2
bolt holes to allow easy access through the
bulbar holes. See instructions in winch user
manual.
20. Determine where the winch control box will
be located and mount the control box. See
instructions in winch user manual for control
box mounting options. If mounting to the top
of the bullbar using the supplied bracket,
check clearance of control box to grill and also
check where the wires will route as if the
wires are passing through the holes in the top
of the bullbar the control box may not be able
to be wired until the bullbar has been fitted as
below.
21. Wire the winch up as per the winch
instruction manual and bolt the winch to the
mounting bracket, ensure the mounting bolts
are not too long and tighten correctly. Route
the wires and connect to battery and also
route the breather hose.
22. Unwind some cable from the winch, and pass
the cable through the fairlead hole in the
bullbar and through the roller fairlead. This
may require removing a circlip from the
fairlead and re installing once the cable is
passed through.
23. Install the roller fairlead into the bulbar.
24. Check the poly bulbar over riders, fog light
and top loop bolts are tight (Do not over
tighten the stainless steel loop mounting
bolts. Do not over tighten the poly bullbar

Dobinsons Springs and Suspension www.dobinsonsprings.com
over riders as they will pull the over riders out
of shape).
25. Fit the new grill bracket (item 10) into place
and refit the grill. The grill tab will locate in
the slot of the new bracket. Place a zip tie
around the rib and the grill and the bracket to
secure tight.
26. Fit the rubber headlight to bumper inserts on
the top of each bar and tighten (Do not over
tighten).
27. With help, fit the bulbar into position and
install nuts and bolts supplied.
28. Align the bar with the vehicle into its correct
position, it is best to sit the grill back in place
so you can align the bar correctly.
29. Once you are happy with the alignment
tighten the 3 nuts and bolts on each side.
30. Once happy with the alignment of the bullbar
drill 2 x 8mm pinning holes on each side of the
bullbar drilling through both the mounting
bracket mounting plate and bullbar mounting
plate. Fix with 8mm bolts and nyloc nuts to
keep the bullbar in its position.
31. If fitting a bullbar with fog lights, the fog lights
can be connected using the original vehicle
fog light wires if fitted. If required, cut the old
fog light wiring plugs off and cut the new fog
light wiring plugs and join. If the vehicle is not
fitted with OEM fog lights the wiring loom
supplied can be used. Follow the wiring
diagram at the end of this manual.
32. Plug the wires into the indicator and parker
light plug. Test all lights and adjust the
position of the fog lights if required
33. Fit the under bar protection kit now with the
bolts supplied.
34. Now cut along the both wheel arch splash
guard so that it is flush with the bottom of the
side protection plate fitting in step 32,
ensuring you do not cut into washer bottle
bracket on the LH side and secure.
35. Check over all nuts, bolts and items removed
during installation.
36. IMPORTANT NOTES: It is important to inform
the customer that headlight adjustment may
also be required due to the change in ride
height. It is also important to inform the
customer that there will be a change in
vehicle handling characteristics. It is also
important to note that due to their nature fog
lights are required to provide a yellow light to
allow clear fog vision. For this reason
Dobinsons bullbars utilise a Halogen bulb.
Halogen bulbs generate a considerable
amount of heat to achieve the yellow colour
and this causes the air inside the fog light lens
to expand and contract. For this reason the
fog light assembly cannot be sealed and has a
small breather on the back. In some cases this
may cause condensation to form inside the
fog light. The customer may choose to seal
the lens of the fog light but must not seal the
rear breather.

Customer Copy: Bullbar Care Instructions
To ensure the surface finish quality it is recommended that the
bullbar be washed and cleaned regularly to prevent build up of
dirt and contaminants which when exposed to the elements can
degrade the surface finish. It is also recommended that the mounting fasteners on the bullbar be checked after
1000km’s. Winch servicing and care should also be carried out as per the winch instruction manual.
Stainless Loop Deluxe Bullbar Loop Care and Maintenance
(Customers with Stainless Loop Deluxe Models Only)
The top loops on your Dobinsons Stainless Loop Deluxe steel bullbar are manufactured from high quality 304 grade
stainless steel. Once formed and welded it is highly polished to provide a high gloss finish. Whilst the material is a
high quality stainless steel, like any other exterior polished surface, care and some maintenance is required to
ensure the surface finish quality.
It is recommended that the stainless loops be kept as clean as possible and is thoroughly washed and dried regularly
to prevent build up of dust and contaminants. This is especially important in coastal and high dust areas. The loops
can simply be cleaned with most regular car cleaning items like a soft sponge, car wash and a chamois, avoid strong
cleaning chemicals. Like many other highly polished exterior metals, over extended periods of time and heavy
weathering can cause some staining of the surface may occur. If this occurs the surface can be simply polished using
the following methods to remove the stains and restore the high gloss surface using simple tools and cheap readily
available polishing items.
Tools Required:
•Electric buffer or Electric drill (an electric/cordless drill is generally more convenient).
•Polishing compound – This can be supplied by Dobinsons Spring and Suspension. Please contact head office
on the details below for polish, as a specific type is used.
•Soft finishing type buffing wheel – The buffing wheel should be a soft, finishing type/Calico loose leaf style to
allow the surface to be polished to a high gloss without further marking the surface. The 2 types of discs
shown below are readily available from most hardware stores (Australian customers – Bunnings etc). The
brand below is Josco, and if purchasing a twin pack ensure that only the finishing buff is used and not the
cutting buff. DO NOT USE METAL OR HARSH BUFFING PADS.

Method
1. The stainless loops may be removed from the bullbar if this makes it easier to work on, however if using a
cordless drill this is not a necessity. If removing the loops, do not over tighten the loop retaining bolts when
re fitting.
2. Ensure the loops are first completely clean and dry.
3. Fit the polishing buff wheel to the drill or buffing tool –take note of the maximum wheel speed and rotation
direction.
4. It is recommended to follow specific instructions on the packaging of the buffing wheel for best results.
However if no instructions are provided the following guidelines can be used:
A). Carefully dress the buff wheel with the compound across the rotating wheel for a few seconds, taking
care not o apply too much compound, it is better to apply a little compound more frequently than to
overdress the buff.
B). Gently buff the work area with the buffing wheel and with light pressure move back and forth across the
job.
C). After polishing use a soft, clean, dry rag to clean the surface and inspect in the light for an even finish.
D). Once complete clean thoroughly again with a sponge and warm water.
Dobinsons Spring and Suspension
www.dobinsonsprings.com