ARB 3423020 - Manual (Page 3)

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ASSEMBLY SEQUENCE FOR BULL BAR INSTALLATION.
1. Remove bumper bar, tie down rings, and tow
hook from the vehicle.
2. Remove the crush cans from the front of the
vehicle. (On 2002 models onward, the crush cans
are welded to the sump guard support cross
member which must be removed)
3. Fit the indicators into bar.
4. Fit number plate bracket to bull bar using 6mm
hardware.
5. Fit control box bracket to bull bar using 8mm
hardware.
6. Fit buffers to bull bar using M8 flange nuts
supplied in buffer kit.
NOTE: DO NOT OVER TIGHTEN.
7. To place the clutch handle in the correct
position, the winch gearbox must be rotated 144
degrees (4 hole spacings), in anti- clockwise
direction when viewed from gearbox end. Place the
winch on its end and remove all gearbox bolts.
Gently raise the gearbox just enough to rotate it.
When the correct position is located, refit all bolts
and tighten.
NOTE: Take care not to lift the assembly more
than a couple of millimetres while rotating to
correct position to avoid unmeshing the gears.
See diagram opposite.
8. Once winch is rotated, positioned winch on
bench face up.
9. Lower bull bar on top of winch and align holes
with each other. Using 1 1/4” x 3/8” bolts and flat
washers from bolt kit, secure the two most upper
holes first and finger tighten. Remove top circlips
from vertical rollers of fairlead and remove pins
and rollers, this is done so there is easy access to
lower bolts.
10. Place roller fairlead in bar cutout over lower
holes and fasten using 1 1/2” x 3/8” bolts and 3/8”
flat washers supplied in bolt kit.
11.When all is positioned, tighten all bolts firmly
and replace rollers, pins and circlips back to roller
fairlead.
If fitting the XP 9.5 winch, continue to step 12,
otherwise, jump to step 19.