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ARB 3921120 - User Manual

ARB 3921120
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03/07/2014 Page 1 of 9 3786418
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: (03) 9761 6622 Fax: (03) 9761 6807
WA:(08) 9244 3553 NSW: (02) 9821 3633 ACT: (02) 6280 7475 SA: (08) 8244 5001 QLD: (07) 3872 3872 NT: (08) 8947 2262 TAS: (03) 6331 4190
ARB PRADO WINCH/NON WINCH BUMPER TO SUIT
GXL, VX AND GRANDE 2003 ONWARDS.
PART No 3921120
5100050 Top Tube Kit
5100160 Buffer Kit – With hole (required when fitting Top Tube)
5100170 Buffer Kit – With no hole
FITTING KIT NO: 6172356
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.
IN THE EVENT OF DAMAGE TO ANY BAR COMPONENT, CONTACT YOUR NEAREST
AUTHORISED ARB STOCKIST. REPAIRS OR MODIFICATIONS TO THE IMPACT
ABSORPTION SYSTEM MUST NOT BE ATTEMPED.
DO NOT USE THIS PRODUCT FOR ANY VEHICLE MAKE OR MODEL, OTHER THAN
THOSE SPECIFIED BY ARB.
DO NOT REMOVE LABELS FROM THIS BAR.
THIS PRODUCT OR ITS FIXING MUST NOT BE MODIFIED IN ANY WAY.
OPTIONAL LIGHT SETS TO SUIT THIS PRODUCT:
- ARB 6821201 Fog Light Kit Suit 3163015
- Up to IPF 900 SERIES FOG OR DRIVING LIGHT SETS
Suits warn 9000lb and 9500lb High Speed winches
Tools Required For Bar Fitment: Basic Tool Kit, 17mm Tube Spanner, Cir-Clip pliers,
Drill, 10mm and 13mm Drill Bits.
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Summary

ARB Prado Winch;Non-Winch Bumper Installation Guide

Important Safety Warnings

Critical safety instructions and cautions for fitting the ARB bumper.

Basic Assembly Procedures

Initial steps for fitting the buffer and securing components.

Chassis Mounting and Brace Fitting

Attaching chassis mount braces and reinforcing bars to the vehicle.

Securing Chassis Mounts and Brackets

Fitting chassis mount brackets, spacers, and ensuring proper brace positioning.

Winch Preparation and Mounting

Rotating the winch gearbox and attaching the winch assembly to the bumper bar.

Control Box and Wiring Installation

Mounting the control box, connecting power cables, and ground wire to the winch.

License Plate and Painting

Attaching the license plate and painting the lower front guard section black.

Final Bar Attachment to Chassis

Positioning the main bumper bar onto the chassis brackets and initial fastening.

Top Tube Attachment and Bar Alignment

Fitting the top tube to the bumper and aligning the bar with specified gaps.

Drilling and Securing Uprights

Drilling chassis holes and securing bar uprights using supplied hardware.

Stone Tray Refitting

Removing the original front stone tray and refitting it with rear bolts only.

Stone Tray and Washer Bottle Guard Fitting

Attaching the ARB stone tray and the washer bottle guard to the bumper assembly.

Light Surrounds and Wiring

Assembling light surrounds and wiring them to vehicle indicator lamps.

Summary

ARB Prado Winch;Non-Winch Bumper Installation Guide

Important Safety Warnings

Critical safety instructions and cautions for fitting the ARB bumper.

Basic Assembly Procedures

Initial steps for fitting the buffer and securing components.

Chassis Mounting and Brace Fitting

Attaching chassis mount braces and reinforcing bars to the vehicle.

Securing Chassis Mounts and Brackets

Fitting chassis mount brackets, spacers, and ensuring proper brace positioning.

Winch Preparation and Mounting

Rotating the winch gearbox and attaching the winch assembly to the bumper bar.

Control Box and Wiring Installation

Mounting the control box, connecting power cables, and ground wire to the winch.

License Plate and Painting

Attaching the license plate and painting the lower front guard section black.

Final Bar Attachment to Chassis

Positioning the main bumper bar onto the chassis brackets and initial fastening.

Top Tube Attachment and Bar Alignment

Fitting the top tube to the bumper and aligning the bar with specified gaps.

Drilling and Securing Uprights

Drilling chassis holes and securing bar uprights using supplied hardware.

Stone Tray Refitting

Removing the original front stone tray and refitting it with rear bolts only.

Stone Tray and Washer Bottle Guard Fitting

Attaching the ARB stone tray and the washer bottle guard to the bumper assembly.

Light Surrounds and Wiring

Assembling light surrounds and wiring them to vehicle indicator lamps.

Overview

  1. Function Description
  2. Important Technical Specifications
  3. Components and Hardware (from Fitting Kit 6172356)
  4. Optional Light Sets
  5. Tools Required for Bar Fitment
  6. Usage Features
  7. Maintenance Features

This document provides fitting instructions for the ARB Prado Winch/Non Winch Bumper, designed for GXL, VX, and Grande models from 2003 onwards. The bumper is identified by part number 3921120, with a fitting kit number 6172356. Optional components include a Top Tube Kit (5100050) and two Buffer Kits (5100160 with a hole for the Top Tube, and 5100170 without a hole).

Function Description:

The ARB Prado Winch/Non Winch Bumper is a front protection bar designed to be installed on specific Toyota Prado models. It serves to enhance the vehicle's front-end protection and provides mounting points for various accessories, including a winch, driving lights, and a license plate. The design ensures that it does not interfere with the operation of the vehicle's SRS Airbag system when installed correctly. The bumper is compatible with winches up to 9000lb and 9500lb High Speed models from Warn.

Important Technical Specifications:

Components and Hardware (from Fitting Kit 6172356):

  • Impact Absorber to Chassis:

    • Bracket Mount Assembly (3756571): 1 unit
    • Bracket Mount Brace RHS (3756645R): 1 unit
    • Bracket Mount Brace LHS (3756645L): 1 unit
    • Captive Nut Plate (3193741): 2 units
    • Nut Cage M12 x 1.75 (6151306): 2 units
    • Bolt M12 x 1.75 x 40mm (6151255): 10 units
    • Nut M12 x 1.75 (6151189): 6 units
    • Bolt M12 x 1.25 x 30mm (6151094): 2 units
    • Washer Flat ½" (4581049): 20 units
    • Washer Spring ½" (4581050): 12 units
    • Spacer 8mm (5846401): 4 units

  • Bar to Impact Absorber:

    • Nut Cage M10 x 1.5 (6151304): 6 units
    • Bolt M10 x 1.5 x 30mm (6151232): 8 units
    • Washer Flat M10 x 2mm (4581040): 10 units
    • Washer Spring M10 (4581048): 8 units
    • Nut M10 x 1.5 (6151026): 2 units

  • Stone Tray to Bar:

    • Stone Tray (6522036): 1 unit
    • Nut Cage M6 (6151300): 4 units
    • Bolt M6 x 20mm (6151180): 4 units
    • Washer Flat Panel M6 (4581084): 4 units
    • Washer Spring M6 (4581036): 4 units

  • Top Tube to Bar (for 5100050 Top Tube Kit):

    • Top Tube assembly (6131516): 1 unit
    • Bolt M12 x 1.75 x 40mm (6151255): 2 units
    • Washer Flat ½" (4581049): 2 units
    • Washer Spring ½" (4581050): 2 units

  • Buffer to Bar (for 5100160 - with hole for Top Tube):

    • Flange Nut M6 (6151128): 12 units
    • Buffer LHS (3162153): 1 unit
    • Buffer RHS (3162154): 1 unit

  • Buffer to Bar (for 5100170 - without Top Tube):

    • Flange Nut M6 (6151128): 12 units
    • Buffer LHS Sahara Bumper (3162471L): 1 unit
    • Buffer RHS Sahara Bumper (3162471R): 1 unit

  • Buffer Lower to Bar:

    • Flange Nut M6 (6151128): 5 units
    • Buffer Lower (3162155): 1 unit

  • Indicators to Bar:

    • Kit Surround For Fog & Indicator Lights (3163015): 1 unit
    • Turn signal / clearance light loom (6821152): 2 units
    • Turn Signal/Clearance Light (6821151L): 1 unit
    • Turn Signal/Clearance Light (6821151R): 1 unit

  • Licence Plate to Bar:

    • Nut Flange M6 (6151128): 2 units
    • Tape Double sided (6781408): 1 unit

  • Winch Cover to Bar:

    • Panel Winch Cover Prado (6522030): 1 unit
    • Screw M6 S/S Button Head (6151256): 2 units
    • Washer Flat M6 S/S (4581304): 2 units
    • Nut Flange M6 (6151128): 2 units

  • Winch to Bull Bar:

    • Rubber Grommet (EG50): 1 unit
    • Bracket Control Box (3756499): 1 unit
    • Bolt M8 x 20mm (6151021): 2 units
    • Washer Flat M8 (4581044): 2 units
    • Nut Flange M8 (6151132): 2 units
    • Cable Black 560mm (BLB560): 2 units
    • Washer Flat M10 x 2mm (4581040): 4 units
    • Bolt 1 ¾" x 3/8" UNC (6151074): 2 units

  • Washer Bottle Guard to Bar:

    • Washer Bottle Guard For Sahara bar (6522031L): 1 unit
    • Washer Bottle Guard For Sahara bar (6522031R): 1 unit
    • Bolt M8 x 25mm Black (6151234): 10 units
    • Washer Flat M8 Black (4581045): 10 units
    • Nut Flange M8 (6151132): 10 units

  • Miscellaneous:

    • Rubber Grommet 3/8" ID (6821132): 2 units
    • Nut Flange M6 (6151128): 2 units
    • Cable Ties (180302): 6 units
    • Plastic Plug 16mm DIA (3162152): 2 units
    • Scotch Lock (180701): 6 units

Optional Light Sets:

  • ARB 6821201 Fog Light Kit (for 3163015 surround)
  • Up to IPF 900 SERIES FOG OR DRIVING LIGHT SETS

Tools Required for Bar Fitment:

  • Basic Tool Kit
  • 17mm Tube Spanner
  • Cir-Clip pliers
  • Drill
  • 10mm and 13mm Drill Bits

Usage Features:

The bumper is designed for straightforward installation, though it requires careful attention to detail and adherence to the provided instructions. Key installation steps include:

  1. Buffer Installation: Position and fasten lower and main buffers using M6 flange nuts. Caution is advised against overtightening to prevent damage to buffer studs.
  2. Nut Cage Installation: Fit M10 and M6 nut cages into the bull bar, and M12 nut cages into the captive nut assembly.
  3. Vehicle Preparation: Remove the front bumper cover, reinforcing bar, and side bumper supports.
  4. Chassis Modification: Drill M8 captive nut holes in the chassis.
  5. Chassis Mount Braces: Install chassis mount braces using M12 bolts, spring, and flat washers, ensuring proper spacing.
  6. Captive Nut Assembly: Insert and provisionally fix the captive nut assembly to the chassis.
  7. Chassis Mount Bracket: Fix the chassis mount bracket to the brace, carefully bending the air-conditioning pipe if necessary.
  8. Winch Gearbox Rotation (if applicable): Rotate the winch gearbox handle for easier access by loosening cap screws and rotating anti-clockwise three hole spaces.
  9. Winch Control Box Wiring: Replace specific cables in the winch control box with supplied BLB560 cables and label them for correct re-wiring.
  10. Winch Mounting: Lift the bar onto the winch and secure it using 1 ½" x 3/8" bolts, spring, and flat washers. Ensure the wire rope spools from the bottom and the gearbox is on the passenger side.
  11. Roller Fairlead Installation: Position the roller fairlead, remove circlips from lower vertical rollers, and fix it to the bar using 1 ¾" x 3/8" bolts, spring, and flat washers.
  12. Control Box Bracket: Fit the control box bracket to the bar using M8 bolts, flat washers, and flange nuts.
  13. Control Box Wiring: Connect the control box to the winch and ground wire, cable-tying all cables to keep them clear of sharp edges and moving parts.
  14. License Plate Attachment: Attach the license plate to the bar using double-sided tape, original screws, and M6 flange nuts.
  15. Vehicle Painting: Mask and paint the lower section under the front guard black on both sides.
  16. Bar Positioning: Position the bar on the chassis bracket with an assistant, fixing it with M10 bolts, spring, and flat washers (do not tighten yet).
  17. Top Tube Installation (if applicable): Attach the top tube to the bar using M12 bolts, flat, and spring washers, tightening to 44Nm (critical).
  18. Final Bar Adjustment: Position the bar with a 25mm gap to the headlights and guards, then tighten all bolts.
  19. Stone Tray Installation: Remove the front stone tray from the vehicle, remove tags, and refit using original bolts. Fit the front of the stone tray to the bull bar using M6 bolts, large panel washers, and spring washers.
  20. Washer Bottle Guard: Fit the washer bottle guard using M8 black bolts, flat washers, and flange nuts. Trim the plastic inner guard liner and attach it to the washer bottle guard with cable ties.
  21. Light Installation: Assemble and install combination light surrounds (p/n 3163015) and wire them to the vehicle's indicator and clearance lamps. Optional fog lamps can be installed at this stage.
  22. Final Checks: Ensure all bolts are tightened and wiring is clear of hot, sharp, and moving parts.

Maintenance Features:

  • Damage Protocol: In case of damage to any bar component, contact an authorized ARB stockist. Repairs or modifications to the impact absorption system are strictly prohibited.
  • Product Integrity: Do not remove labels from the bar. The product or its fixing must not be modified in any way.
  • Hardware: Only use the supplied hardware for installation.
  • Compatibility: The product is designed for specific vehicle makes and models as specified by ARB. Using it on other vehicles is not recommended.

ARB 3921120 Specifications

General IconGeneral
BrandARB
Model3921120
CategoryAutomobile Accessories
LanguageEnglish

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