ARB 3421530 Combination Bumper Instructions

ARB 3421530 Combination Bumper

Product Information

Specifications

• Part Number: 3421530 / 3421540
• Fitting Kit No : 6174125/6174126
• Product Description: ARB WINCH BULL BAR
• Suited to Vehicle/s : TOYOTA 4 RUNNER YEAR MODELS 03 ON

Product Usage Instructions

Installation Warnings and Guidelines

• This product must be installed exactly as per the provided instructions using only the hardware supplied.
• Do not attempt repairs or modifications to the impact absorption system in case of damage; contact an authorized ARB stockist.
• Use the product only for the specified vehicle make and model by ARB.
• Do not remove labels from the bull bar or modify the product in any way.
• The installation may require specialized tools and should be done by trained personnel.
• Always work safely, check correct operation/clearances of all components during installation, and tighten fasteners to specified torque.

General Care and Maintenance

• Treat the bar with Carnauba-based polish on all exposed surfaces every six months or after exposure to contaminants.
• Conduct a thorough visual inspection of the bar annually, ensuring all bolts and components are torqued correctly, and replace damaged parts as needed.

Fitting Requirements

• Required Tools: Metric socket and spanner sets (8-25mm range), External Circlip pliers, Screwdrivers (Philips and Flat blade), Cold chisel, Hammer, Power Drill (13mm capacity), 10mm and 13mm drill bits.
• Safety Items: Protective eyewear and hearing protection should be worn during fitting to avoid any potential hazards.

SPECIFICATION

• Part Number : 3421530 / 3421540
• Fitting kit No: 6174125/6174126
• Product Description: ARB WINCH BULL BAR
• Suited to vehicle/s : TOYOTA 4 RUNNER YEAR MODELS 03 ON

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 the specified torque

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:

FITTING REQUIREMENTS REQUIRED TOOLS FOR FITMENT OF PRODUCT

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

OPTIONAL LIGHT SETS TO SUIT THIS PRODUCT

• ARB 6821201 FOG LAMP SUIT 3163015
• Up to IPF 900 SERIES FOG OR DRIVING LIGHT SETS

PARTS LISTING

PARTS LISTING

APPLICATION.| PART NO.| QTY| DESCRIPTION
 | 3756893| 1| Bracket Mount Assembly
 | 3756851R| 1| Bracket Mount Brace RHS
 | 3756851L| 1| Bracket Mount Brace LHS
 | 3193741| 2| Captive Nut Plate
 | 6151306| 2| Nut Cage M12 x 1.75
Mount Assembly To Chassis| 6151255| 8| Bolt M12 x 1.75 x 40mm
 | 6151189| 6| Nut M12 x 1.75
 | 6151094| 2| Bolt M12 x 1.25 x 30mm
 | 4581049| 18| Washer Flat M12
 | 4581050| 10| Washer Spring M12
 | 5846401| 4| Spacer 8mm
 | 6151357| 10| SEMS Bolt M10 x 1.5 x 30mm
Bull Bar To Mount Bracket Assy| 4581040| 10| Washer Flat M10 x 2mm
 | 6151026| 10| Nut M10 x 1.5
 | 6542091| 1| Stone Tray
 | 6151300| 4| Nut Cage 6mm
Stone Tray to Bull Bar| 6151213| 4| Bolt M6 x 20mm
 | 4581084| 4| Washer Flat M6
 | 4581287| 4| Washer Spring M6

Indicators To Bull Bar

| 3163015

6821152

180701

6821192

6821151R

6821151L

| 1

2

6

2

1

1

| Combination Light Surround Kit Turn signal/clearance light loom Scotch lock

Bulb 12V 10W BA15S

Turn Signal / Clearance Light Turn Signal / Clearance Light

 | EG50| 1| Rubber Grommet
 | 3756499| 1| Bracket Control Box
 | 6151021| 2| Bolt M8 x 20mm
Winch To Bull Bar| 4581044

6151132

| 2

2

| Washer Flat M8

Nut Flange M8

 | BLB560| 2| Cable Black 560mm
 | 4581040| 4| Washer Flat M10 x 2
 | 6151074| 2| Bolt 1 ¾” x 3/8” UNC
 | 3162470R| 1| Buffer
Buffers to Bull Bar| 3162470L| 1| Buffer
 | 6151128| 12| Nut M6 Flanged
 | 6821189| 2| Grommet Nylon Nut
Number Plate To Bull Bar| 6151384| 2| Screw
 | 6781408| 1| Tape Double sided
 | 6151132| 10| Nut Flange M8x1.25P
Wing Under Panel Kit (3421540 only)| 6151234

4581045

6522670R

| 10

10

1

| Bolt M8x1.25×25 BZ Washer Flat M8x17x1.2 BZ

Panel Washer Bottle Guard RH

 | 6522670L| 1| Panel Washer Bottle Guard LH
 | 6821132| 2| Rubber Grommet 3/8” ID
Miscellaneous| 180302| 8| Cable Ties
 | 3162152| 2| Plastic Plug 16mm DIA

FITTING PROCEDURE

1. Undo bumper light electrical connections and then remove the front bumper cover from the vehicle NOTE: For 03-05 Models only, follow steps 2 to 4 and 42 to 44 regarding plastic trim support.

2. Remove plastic support from inside the OE bumper cover

3. With the trim piece fitted to the OE bumper cover asshown, mark out and draw a line 25mm (1”)from the leading edge of the lower grille trimapprox. 864mm (34”) long

4. Remove trim and then cut out plastic panel along marked line from OE bumper facia, set this piece aside for fitting later.

5. Remove a trim piece and support bracket

6. With the trim piece removed, mask the area around the headlight and the front guard paint the lower section under the front guard black

7. Remove the front bumper reinforcing bar.
   NOTE: Retain the 8 x flange nuts removed for fitment of the bull bar chassis mount.

8. Remove the front fasteners only from the stone tray. Retain fasteners for reuse.

9. Using the 13mm drill bit and power drill, drill out the M8 captive nut located at the outboard side of the chassis as shown, on both sides of the vehicle
   Warning: Drilling operations can result in flying metal debris, safety glasses should be worn.

10. Check that the nut body is completely removed, if it is not cleared, use a cold chisel and hammer chisel the remainder off
    Warning: Hammering and chiselling operations can result in flying metal debris, safety glasses should be worn

11. Fit an M12 cage nut to each of the captive nut plates 3193741

12. Fit the chassis mount braces to the vehicle using the M12 x 30mm fine-pitched bolt, M12 spring and flat washers supplied in the lower hole. Use an M12 flat washer as a spacer between the brace and the chassis at the upper hole and fix with an M12 x 40mm bolt M12 spring and flat washers and M12 x 1.75 nut. Do not tighten the bolts.

13. Insert the captive nut assembly through the front of the chassis and line it up with the hole at the end of the mounting brace. Fix in place with the M12 x 1.75 x 40mm bolt, M12 flat and spring washers. Break off the end of the captive nut plate. Do not tighten yet.

14. Hold the 8mm spacer against the chassis mount brace forward-facing surface and position the brace so that the spacers sit just below the surface of the chassis front face. Tighten the bolts

15. Fit the chassis mount bracket to the chassis using the original flange nuts removed with the bumper reinforcing bar. Centre the chassis mount bracket and tighten it.
    CAUTION : When fitting the Chassis mounting bracket carefully bend the air-conditioning pipe out of the way

16. If required, carefully bend the piping clear of the mount bracket assembly.
    CAUTION: Piping must not rub on sharp edges, secure with a cable tie and protective sheath if required.

17. Fix the chassis mount bracket to the chassis mount brace using M12 x 40mm bolts, M12 spring and flat washers, the 8mm spacers and M12 x 1.75 nuts. Tighten bolts
    NOTE : If fitting the winch continue through step 18, if not skip to step 30

18. For ease of access, the winch gearbox handle needs to be rotated. To do this undo all the cap screws, carefully lift the gearbox clear of the winch body so as not to damage the gasket. (Do not lift the gearbox more than a couple of millimetres) Rotate the gearbox anti-clockwise three-hole spaces. Re-fit the caps-crews.

19. Using a 12mm drill bit, drill two new holes in the roller fairlead 25mm below the original holes.
    New hole 25mm lower
    Warning : Drilling operations can result in flying metal debris, safety glasses should be worn

20. Remove the three screws from the control box and remove the cover.

21. Replace the two cables marked “A” and “F1” and replace them with the two cables (BLB560) supplied with the fitting kit. Label the cables the same as the original to assist in the wiring of the winch

22. Place the winch on a table with the feet facing up and using an assistant; carefully lift the bull bar on top of the winch.

23. Attach the winch to the bull bar using two 1 ½” x 3/8” bolts from the winch fitting kit, 3/8” spring washer and 3/8” flat washers in the top holes.

24. Fit the 4 x M6 cage nuts from inside of the lower flange on the pan, where the stone tray will bolt up.
    NOTE: Access to this area for cage nut fitment will be restricted once the RFL is fitted so it is important to insert these now

25. Position the roller fairlead, remove the circlips from the lower of the vertical rollers and push the pins up to give access to the lower bolts.

26. Fix the roller fairlead to the bar using the 1 ¾” x 3/8” bolts, spring and flat washers

27. Fit the control box bracket to the bull bar using two M8 x 20mm bolts, M8 flat washers and M8 flange nuts.

28. Fit the control box to the control box bracket and connect the power cables to the winch as per the winch instructions.

29. Connect the ground wire to the tension bar of the winch.
    CAUTION : Cable-tie all cables together and keep all cables clear of sharp edges and all moving parts.

30. Insert square grommets into holes in front of the bar for number plate fixing. Place the double-sided tape along the top edge of the number plate. Using supplied black screws, attach the number plate to the bull bar.
    NOTE: If a winch is not fitted, the number plate can be located lower on the bar front to cover RFL opening

31. Fit the buffers to either side of the bull bar using 6 x M6 flange nuts. Do not over-tighten

32. With the help of an assistant position the bull bar on the chassis bracket and fix it with six M10 x 30mm bolts, an M10 spring and flat washers.
    CAUTION: Nip up bolts, but do not tighten them yet

33. Position the bull bar so that there is an even gap of approximately 20-25mm from the top face of the bar to the underside of the body edge. Then tighten all the bolts.

34. With the bull bar in position drill Dia10mm pinning holes, one through the pilot hole in the mount bracket and one through the hole upright for both sides of the mounts
    Warning: Drilling operations can result in flying metal debris, safety glasses should be worn

35. Fix in place using two M10 x 30mm SEMS bolts, M10 Flat washers and M10 x 1.5 nuts per side

36. Fit the bull bar stone tray by sliding the tray under the front of the vehicle’s original stone tray and fixing in place with the original bolts from the vehicle’s stone tray.

37. Fit the front of the stone tray to the bull bar with four M6 x 20mm bolts, M6 large panel washers and M6 spring washer

38. Replace 21W light bulbs for indicator (yellow reflector side) in supplied indicator/run lamp assemblies with 10W bulbs from the fitting kit

39. Assemble and install combination light surrounds (p/n 3163015) as per instructions no. 3786421 supplied with surround kit. Note: Optional fog lamps can be installed at this point as per fitting instruction no. 3783315 supplied with fog lamp kit 6821201

40. Wire up indicator and run lights using loom extensions supplied in fitting kit.
    OTE: The 4 Runner has a two-wire circuit for indicators. The bull bar indicator and run lamps on each side are to be wired to operate in parallel. The ARB-supplied wiring loom has Red and Green for power to indicator and run lamps – join these wires together. Other wiring details supplied with accessories. Toyota 4 Runner wiring colours:

41. RH White w/Black Stripe – Ground

42. Red w/Yellow stripe – Power

43. LH White w/Black Stripe – Ground

44. Red w/Green stripe – Power

45. Fit wing under panels using panels and M8 fasteners supplied

46. Take cut-out trim from OE bumper (Step 4) tuck leading edge of the plastic trim under the back edge of the bumper and use OE retaining clips in the OE holes to hold the bumper piece into place

47. Snap lower grille trim into place onto the bumper piece

48. Finished installation of the trim piece

When finished make sure all bolts are tightened and that all wiring is clear of hot, sharp and moving parts.

• Also supplied in the kit are two 3/8” rubber grommets and two 16mm plugs. The rubber grommets are for the two holes in the top pan if lights are being fitted. The two plastic plugs are for the holes in the top surface of the wings if no CB aerials are going to be connected.
• NOTE : Fog lamps shown fitted to the bull bar below are optional accessories, ARB P#9249FCK 100mm 55WATT FOG LAMP KIT

CONTACT

• Corporate Head Office42-44 Garden St
• Tel: +61 (3) 9761 6622
• Kilsyth, Victoria
• Fax: +61 (3) 9761 6807 AUSTRALIA 3137
• Australian enquiries sales@arb.com.au
• North & South American enquiries sales@arbusa.com
• Other international enquiries exports@arb.com.au
• www.arb.com.au

References

• ARB 4x4 Accessories Australia - Your Partner In Adventure
• ARB 4x4 Accessories Australia - Your Partner In Adventure

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