ECB BIG TUBE BH44SY User manual

© Copyright –ECB Pty Ltd –2018 1
BH44SY
FITTING INSTRUCTIONS
RODEO RA 03/03–12/06 LT BIG TUBE™PROTECTION BAR WITH 9000LB WARN WINCH
MOUNTING BRACKET VEHICLE FRONTAL PROTECTION SYSTEM (VFPS)
FOR AIR BAG AND ADR COMPLIANT VEHICLES
Check installation hardware before commencing.
1. Lift bonnet.
2. Remove grille. Four clips along top, one PK self-tapper just below Holden badge and two push in-out clips at
bottom.
3. Remove bumper cover. Five plastic clips along top under grille area, two 10mm head self-tappers and one plastic
clip (each side). Two plastic clips at bottom.
4. Remove cross member from front of chassis. Four 14mm head bolts. See figure 1. Remove two bumper cover
lower support brackets from vehicle. One 10mm head bolt (each side).
5. Remove front 14mm head bolts from under chassis protection plate and let hang down.
6. Remove grille / bumper cover support from vehicle, ten 10mm head nuts and two plastic inner guard clips (one
each side). Cut sides off beside outer grille mount. See figures 2 and 3. Paint exposed metal and refit to centre of
vehicle. Refit grille.
7. Attach ECB steel mounting brackets (supplied) to front of chassis. Use M10 x 40 x 1.25 bolts/washers (supplied).
See figures 4 and 5. FINGER TIGHTEN ONLY.
8. Centre and level steel mounting brackets on vehicle, See figures 6 & 7. Ensure sufficient distance apart for
protection bar to mount on inside of steel mounting brackets. Check protection bar measurement. Refit chassis
protection plate over steel mounting brackets. Use M10 x 35 x1.25 bolts/washers (supplied). TIGHTEN steel
mounting brackets in position.
NOTE: Two extra 3/8 flat washers are supplied for spacers between lower welded bracket on steel mount and
chassis if required.
NOTE: Once M10 x 40 bolts are tight, fit one M10 nut (supplied) over each bolt TIGHTEN. See figure 8
9. Place winch mounting bracket (supplied) on top of plates welded to steel mounting bracket. Use 7/16 x 1 ½ bolts,
nuts and washers (supplied). Centralise on vehicle and TIGHTEN ALL BOLTS/NUTS. See figure 9.
10. Attach roller fairlead to winch mounting bracket. Use original 7/16 x 1 winch bolt, nut and washer. Feed 7/16 x 1
bolt, washer from inside. Attach nut and washer on outside. TIGHTEN.
11. Attach winch to winch mounting bracket, feed winch cable through roller fairlead as installing. Use original winch
3/8 x 1 ¼ bolts and spring washer with 3/8 flat washers (supplied). TIGHTEN WINCH IN POSITION. See
figure 10.
12. Attach control box bracket (supplied) to control box. Place ¼ flat washer (supplied) over studs, then control box
bracket, then ¼ flat washer (supplied). Use original nuts. See figure 11.
NOTE: Control box is to fit hard up against inside of protection bar. TIGHTEN control box bracket flush with
8mm head control box self-tappers at top.
REPLACES: 25.02.10
REVISED: 17.01.18

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13. Connect all winch wiring. Ensure wiring is clear of winch wire rope and routed in such a manner to avoid damage
from heat and or sharp edges. Use four 200mm long zip ties (supplied).
NOTE: Use 3mm clip lock trim on grille support to protect winch cables. See figure 12.
14. Position control box on top of winch. See figure 13.
15. Splice ECB indicator/park light wiring into original wiring loome. Use cable locks (supplied).
16. Attach infill trim (supplied) to top sides of ECB protection bar. Attach 1000mm of 6mm clip lock trim (supplied)
to centre of protection bar. Attach 3mm clip lock trim (supplied) to skirt. NOTE: On infill trim, trim 30mm off
lower edge so trim will sit over end of protection bar. See figures 14, 15 and 16. Trim excess off end to follow
protection bar. See figure 18. NOTE: Seal any exposed edges of trim with silicone or similar to avoid corrosion
of inner steel.
17. Fit ECB LED indicator / park lights (supplied) into protection bar as per instructions supplied with the LED
indicator kit. NOTE: Ensure park light is to outside. See figure 19.
18. Attach ECB fog lights to protection bar. Place M6 x 20 bolts, spring washers (supplied) through light mount from
inside and attach nut to top. Slide assembly into light mount in Protection bar and centralize light to
hole.TIGHTEN FIRM ONLY. Fit ECB fog light trims (supplied) to protection bar. NOTE: Wider part of trim
faces to centre. See figure 20.
19. Remove air vents from protection bar to allow access for bolts and nuts.
20. Attach protection bar to inside of steel mounting brackets. Attach control box bracket to protection bar as
installing. Use ¼ x 1 bolt, nylock nut and washer (supplied).
NOTE: Feed ¼ x 1 bolt from underside. Align control box with cut out in protection bar and TIGHTEN bolts and
nuts. See figure 21.
21. Slide protection bar further in to mount hole positions. Use ½ x 1 ½ bolts, nuts and washers (supplied).
NOTE: For lower front hole on drivers’ side place spring washer on bolt head with flat washer (this will space bolt
off winch motor). CHECK CLEARANCE.
22 Align protection bar with approximately 3-5mm clearance off grille and infill trim just contacting headlights. See
figures 22, 23 and 24.
23. TIGHTEN ALL BOLTS/NUTS.
24. Trim plastic inner guard, See figure 25, and fold around steel inner panel and over stud. Use 6mm (10mm head)
nut previously removed with ¼ flat washer (supplied). See figure 26.
25. Connect ECB indicator/park light. Secure to original wiring with zip ties (supplied). Ensure wiring is routed in
such a manner to avoid any sharp edges etc.
26. Connect ECB fog lights check operation.
27. Aim ECB fog lamps at low beam height. TIGHTEN IN POSITION.
28. Refit air vents to protection bar. NOTE: Two lower air vents must be trimmed down to avoid fouling on winch
mounting bracket.

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NOTE: TO OPERATE CLUTCH LEVER ON WINCH REMOVE PASSENGER SIDE AIR VENT.
SEE FIGURE 26
ENSURE THESE INSTRUCTIONS ARE LEFT IN VEHICLE AND VEHICLE OPERATOR IS AWARE OF
USE OF WINCH.
Note: When fitting/refitting the licence plate to the vehicle, ensure there is no obstruction to licence plate vision in
accordance with local authorities. If required relocate licence plate to an alternate location.
Further VFPS Notes:
a) Do not attach VFPS to the vehicle using anchorages not intended for this purpose (e.g. engine mounting bolts).
b) Do not use this product for any vehicle make or model, other than those specified by the VFPS manufacturer.
c) Do not remove the plaque or label from the VFPS.
d) Do not modify the structure of the VFPS in any way.
e) No accessory or fitment should project forward of the VFPS forward profile.
f) ENSURE THESE INSTRUCTIONS ARE LEFT WITH VEHICLE OWNER AND/OR OPERATOR.
FITTING KIT
2 –Steel mounting brackets.
2 –150mm lengths 3mm black clip lock.
1 –Winch mounting bracket.
1 –200mm length 3mm black clip lock.
1 –Control box bracket.
1 –1000mm length 6mm clip lock.
4 –M10 x 40 x 1.25 bolts/nuts.
6 –Cable locks.
2 –M10 x 35 x 1.25 bolts.
6 –¼ flat washers.
10 –10mm flat washers.
2 –¼ x 1 bolts.
6 –10mm spring washers.
2 –¼ nylock nuts.
6 –½ x 1 ½ bolts/nuts.
4 –150mm zip ties.
12 –½ flat washers.
4 –200mm zip ties.
6 –½ spring washers.
2 –3mm trimmed air vents for protection bar skirt.
6 –7/16 x 1 ½ bolts/nuts.
2 –ECB fog lights and wiring kits.
12 –7/16 flat washers.
2 –ECB fog light trims.
6 –7/16 spring washers.
2 –M6 x 20 bolts.
1 –ECB LED Indicator / Park light kit.
2 –M6 nuts
2 –680mm lengths infill trim.
2 –M6 flat washers.
2 –M6 spring washers.

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Figure 1
Figure 2
Figure 3
Figure 4 –Passenger side shown
Figure 5 –Drivers side shown
Measuring from steel mounting bracket to centre of body
Figure 6
Cross member
Cut grille support sides
off under headlights
Cut sides off

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Figure 7
Figure 8
M10 lock nut
Figure 9
7/16 x 1 ½
bolt, nut and
washer
Figure 10
3mm clip lock trim to protect winch cables
Figure 12
Figure 11
M10 x 40 bolt
Winch mounting
bracket

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Figure 18
Figure 15
Figure 17
Figure 14
Attach 3mm clip lock trim each side of cut out
Figure 13
Trim 30mm off
lower edge.
Figure 16
Black clip lock trim
Top
Clip lock trim in centre
Infill trim
Trim to follow protection bar angle

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Figure 19
Figure 21
Installing control box to protection bar
3-5mm clearance off grille
Figure 22
Figure 23
Figure 24
Infill trim just contacting headlights
Figure 20
M6 bolt
3-5mm clearance
off grille
Stainless steel self-tappers

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Figure 25
Trim off
Figure 26
Figure 27

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We value your comments
Dear Fitter,
ECB would like to know how you went with the installation of this product. We value your comment and may need to
contact you to clarify some details so please complete your contact details clearly.
We would appreciate if you could complete as many of the following details as possible.
Your Name:
Your contact No.
Product Part No.
Product Invoice No.
Product Description:
Make, model, and year of vehicle:
Product Work Order No.
Company your from/Company product purchased from:
Date of Fitment: ____/____/____
Yes No
Was the fitting hardware supplied complete?
If no what was not supplied
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
Yes No
Did the installation go well?
Please provide comments
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
Please draw diagrams if you need to.
Post to Fax to
Reply Paid 122 (07) 3283 1168
PO Box 122
Margate QLD 4019

© Copyright –ECB Pty Ltd –2018 10

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DESPATCH CHECKLIST
BH44SY
ICZBKCH44 *ICZBKCH44*
Work Order #
Finish:
Transport:
Due Date:
O2 –Steel mounting brackets.
O1 –Winch mounting bracket.
O1 –Control box bracket.
O1 –Bolt Kit.
O1 –ECB LED Indicator / Park light kit.
O2 –ECB fog lights and wiring kit.
O2 –ECB fog light trims.
O2 –680mm lengths infill trims.
O2 –150mm lengths 3mm clip lock.
O1 –200mm length 3mm clip lock.
O1 –1000mm length 6mm clip lock.
O2 –3mm trimmed air vents for protection bar skirt –Fitted to bar (from fitting kit).
O2 –ECB overriders –Fitted to bar.
O2 –6mm air scoops –Fitted to bar.
All parts checked and completed by:
Nut and bolts: __________________________Date__/__/__
Order control: __________________________Date__/__/__
Final wrap check: __________________________Date__/__/__
Is this product “the best it can be” Yes ______/______
Wrapper’s initials / Checker initials
If NO fix before continuing

© Copyright –ECB Pty Ltd –2018 12