ARB 2237010 Fitting Instructions Manual

Fitting instructions# 3789248 Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd Part Number: 2237010-2237020-2237030 Product Description: Modular Bar Suited to DODGE RAM 2500/3500 2012 on vehicle/s: 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 specified torque ARB 4x4 ACCESSORIES Corporate Head Office 42-44 Garden St Tel: +61 (3) 9761 6622 Kilsyth, Victoria Fax: +61 (3) 9761 6807 AUSTRALIA 3137 Australian enquiries [email protected] North & South American enquiries [email protected] Other international enquiries [email protected] www.arb.com.au

Fitting instructions# 3789248 Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd 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:  Prior to exposure to the weather your bar should be treated to a Canuba based polish on all exposed surfaces. It is recommended that this is performed on a six monthly basis or following exposure to salt, mud, sand or other contaminants.  As part of any Pre Trip Preparation, or on an annual basis, it is recommended that a thorough visual inspection of the bar is carried out, making sure that all bolts and other components are torqued to the correct specification. Also check that all wiring sheaths, connectors, and fittings are free of damage. Replace any components as necessary. This service can be performed by your local authorized ARB Stockist. FITTING REQUIREMENTS REQUIRED TOOLS FOR FITMENT OF PRODUCT: METRIC SOCKET SET METRIC RING AND OPENEDED SOCKET SET ELECTRIC DRILL 13MM CAPACITY 10MM DRILL BITS RUST INHIBITING PAINT PHILLIPS AND FLAT BLADE SCREW DRIVER TAPE MEASURE HYDRAULIC LIFTING PLATFORM OR ANOTHER PERSON. SHARP CHISEL AND PLASTIC CUTTING SAW TORQUE WRENCH 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: SIZE Torque Nm Torque lbft M6 9Nm 7lbft M8 22Nm 16lbft M10 44Nm 32lbft M12 77Nm 57lbft  ARB INTENSITY LIGHTS, UP TO 900 SERIES ROUND OR 800 RECTANGULAR IPF DRIVING OR FOG LAMPS SUIT THIS PRODUCT  BAR IS DESIGNED TO ACCOMMODATE WARN ZEON 12 AND WARN 16.5TI WINCHES

Fitting instructions# 3789248 Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd MODULAR BAR OPTIONS OPTION 1: BAR OPTION 2: BAR AND TOP FRAME OPTION3 : BAR, TOP FRAME AND OUTER FRAMES

Fitting instructions# 3789248 Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd PARTS LISTING APPLICATION PART NO QTY DESCRIPTION CENTRE PAN ASSY 5237010 3314965 1 PAN ASSY DODGE RAM 3759359 2 BKT ASSY CHASSIS DODGE RAM 3752000 1 BRKT LICENSE 3759288 1 BRACKET FAIRLEAD MOUNT F TRUCK 3759363 1 BRACKET DEFLECTOR DODGE RAM 6522928 1 GRILLE ASSY DODGE RAM 6522951 1 PANEL COVER DODGE RAM 3194637 1 NUT PLATE ASSEMBLY DODGE RAM 3163073 2 BLANKING PLUG 12.7mm 3163091 4 BLANKING PLUG 17.4mm EG50 2 RUBBER GROMMET 180302 4 CABLE TIES 5848409 2 PACKER CHASSIS DODGE RAM 5846401 8 WASHER FLAT M12 X 8MM 6151542 4 BOLT M10 X 40 SEMS 4584326 8 WASHER SPRING M12 BLACK 6151552 8 BOLT M12 X 60 BLACK 6151428 8 M12 X1.175 FLANGE NUT 6151357 11 BOLT M10 X 30 SEMS 6151321 11 NUT FLANGE M10X1.5 4584328 6 WASHER F M8 x 19 x 1.2 6151256 8 SCREW M6X16 BUTTON HEAD S/S 6151561 8 NUT FLANGE M6 6151546 6 BOLT HXHD M8 x 1.25 x 25 GR8.8 6151548 6 NUT FLANGE M8 x 1.25 GR8.8 6151184 2 M8x30 SHCS SS 4581094 2 WASHER SPRING M8 x 3/32 x 3/32 SS 4581081 2 WASHER FLAT, M8 SS 4581304 8 WASHER FLAT, M6 SS WINGS 5137010 3131474R 1 WING ASSY DODGE RAM RIGHT 3131474L 1 WING ASSY DODGE RAM LEFT 3500590 1 FOG LIGHT KIT 4681485 1 BRACE WING RIGHT 4681485L 1 BRACE WING LEFT 4581011 10 WASHER FLAT, M12 x 27 x 4 6151480 10 NUT FLANGE M12 X 1.25 ZP 6151321 8 NUT FLANGE M10 x 1.5 ZP 6151357 8 BOLT SEMS M10 X 30 ZP Gd 8.8 3163073 2 PLUG BLANKING BLK 17.4mm 6151094 10 BOLT M12 x 1.25 x 30 Gd 8.8 ZP 4581040 8 WASHER FLAT, M10 x 25 x 3 ZP

Fitting instructions# 3789248 Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd PARTS LISTING cont. TOP FRAME 5137020 5665933 1 FRAME ASSY DODGE RAM 5665935 2 UPRIGHT END PANEL DODGE RAM 3759392 2 BKT ASSY CENTRE FRAME 4581094 24 WASHER SPRING M8 x 3/32 x 3/32 SS 4581081 24 WASHER FLAT, M8 SS 5811060 12 SLEEVE M8 THREAD F TRUCK 6151263 24 SCREW M8 X 1.25 X 20 S/S SHCS 6151671 4 SCREW M12x1.75x40 SHCS SS 4584354 4 WASHER FLAT M12 SS 4584355 4 WASHER SPRING M12 SS OUTER FARMES 5137030 6136367R 1 FRAME ASSY OUTER DODGE RAM RIGHT 6136367L 1 FRAME ASSY OUTER DODGE RAM LEFT 4581011 2 WASHER FLAT, M12 x 27 x 4 6151255 2 BOLT M12 x 1.75 x 40 Gd 8.8 ZP 4581064 2 WASHER SPRING M12 TZP480 VEHICLE PREPARATION DEPENDING ON THE MODEL, THERE ARE TWO WAYS OF RETAINING THE BUMPER. Bumpers are mounted in 2 ways, Inward facing bolt plate that requires the removal of the Intercooler and Outward facing bolt plate that needs notching out to allow pinning of the mounts to the chassis in final steps. Outward Bolt Plate requires Cut out for pinning mounts to chassis BOLTS INWARDS BOLTS OUTWARDS Inward Bolt plate Requires Intercooler Removal

Fitting instructions# 3789248 Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd VEHICLE PREPARATION 1. Disconnect Battery terminal. 2. Remove the License plate and set aside. 3. Remove plastic plugs from radiator top cover. 4. Remove the 4 screws on top of grille and pull the grille outwards to remove. 5. Disconnect the Fog light loom plug, from behind the bumper. 6. Vehicles with Outward facing bolt plate, proceed to step 13 7. Remove the Anti-Intrusion Brackets from both sides of the chassis and set aside. 8. Undo the hose clamps to the intercooler, one per side. 9. Remove the bolts from the Intercooler retaining brackets, two per side. As shown 10. Remove the Intercooler assembly and set aside. 11. Remove the plastic shroud from the Intercooler.

Fitting instructions# 3789248 Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd 12. Undo the Bumper retaining bolt plates as described in step1 , on each side and with assistance, remove the Bumper and set aside. 13. Remove the Fog light loom from the Bumper and set aside. 14. Remove the Tow Hooks and retain. MAIN BUMPER INSTALLATION 15. Models with Outward facing bolt plate require the bolt plate to be cut as shown, to later access pinning bolt. Paint cut edge with rust preventative paint. 16. Place the Bullbar mounts onto the chassis and re insert the bolt plates in the same direction as they were removed. Refer to step 1 for details. 17. Loosely fasten with the original nuts. 18. Insert the nut plates (1 per side) Note the orientation of the plate to the chassis in photo 2 (shown without mounts for clarity). The nut plate remains loose at this stage Phot 1 shows bolt plate for inward facing configuration. 60mm 20mm 1 2

Fitting instructions# 3789248 Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd 19. Insert the chassis packers between the inner Mount face and the outer chassis face ensuring the packer slots over the mount bolts. 1 per mount. 20. Ensure the mounts are as far forward as possible and tighten the Mount bolts until the packers are firm. Do not tighten to specified torque at this stage. BAR PREPARATION 21. If Installing a winch, fit the RFL bracket to the bar using 4 M10 x 30 SEMS and flange washers as shown. 22. Fit the Roller Fairlead to the Bracket using 2 M10 x 30 SEMS and flange nuts. 23. If Installing Warn 16.5TI , fasten the control box to the RFL bracket using 2 M8x30 ss bolts, spring washers and flat washers. 24. Load the winch onto the Bar and fasten from underneath using the fasteners supplied with the winch. Refer to winch manufactures installation manual for wiring and fitment connections. For large frame Warn winches (including 16,500lb), tighten mounting bolts to 50-55 ft. lbs (68-78 Nm). For Warn Zeon winches, tighten mounting bolts to 30-35 ft (41-47 Nm).

Fitting instructions# 3789248 Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd 25. If fitting a Zeon 12 a portion of the grille will need to be removed to accommodate the top cap of the winch. Tape the lower centre section of the grille. 26. Measure and mark the vertical centre line of the grille and mark the cut out as per photo. 27. Trim with a suitable saw and de-bur the sharp edges. 28. Re-fit the grille and if necessary trim more to achieve at least 10mm clearance around the top cap of the winch. 29. Insert the rubber grommets into the Centre section, 1 per side. BAR INSTALLATION 30. If removed at steps 8-11,Re-install the Intercooler and anti- intrusion Brackets using original fasteners. 31. With assistance, fasten the Centre Pan Assembly to the Mounts using the M12x60mm bolts, with spring washers through the original tow hook then loosely fasten behind the mount with M12 x 8mm thick washers and original nuts. 4 per side. 32. From underneath, fasten the back of the centre section to the Chassis mounts with 2 M10x30SEMS bolts and flange nuts. 33. Align the Centre assembly so as the top face sits horizontal. Tighten all nuts to specified torque. NOTE: Ensure there is at least 20mm clearance between the Bar and Radiators. Front Face of Bar is designed to rake towards the vehicle along lower edge.

Fitting instructions# 3789248 Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd 34. If not installing a winch, place the grille panel in from behind the bar and fasten with the 6 M8 bolts, washers and flange nuts. 35. Before fitting the wings to the centre section, the vehicles fog light loom needs to be modified to suit the ARB fog lights. Using a sharp chisel, cut out rib from plug. Place plug sideways on bench and slice out the rib as shown. ALLWAYS CUT AWAY FROM YOUR HANDS Check loom fits ARB Fog light plugs. If not more will need to be trimmed from rib. 36. Insert the fog lights into the wing from the front, locating into the three positions as shown.

Fitting instructions# 3789248 Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd WING INSTALLATION 37. Using the M12x35 fine thread bolts,flat washers, spring washers and flange nuts, bolt the wing to the centre section aligning al the front faces and tighten . 5 per side. M12 - 77 Nm. 38. Fit the wing braces from the centre section to the wing, using the M10 x 30mm SEMS and Flange nuts. 4 per side. 39. Ensure there is a parallel gap between the body and the top face of the wing of around 15mm. The chassis mounts may have to be loosened to achieve this. Tighten all bolts to specified torque. 40. Connect the Fog light loom to the vehicle harness and closest fog light. Feed the loom through the large rubber grommets and connect to other fog light. Cable tie loom to wing brace and centre section. M10 - 44 Nm.

Fitting instructions# 3789248 Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd CENTRE SECTION INSTALLATION 41. At this stage tighten all fasteners to specified torque. 42. Place the top section onto the Centre assembly and locate using the M12 cap screws, spring washers and flat washers. 43. With assistance locate the nut plate under the centre section fasten the M12 bolts to the plate. 44. Take the 12 threaded sleeves and the 24, M8 cap screws, spring and flat washers and from the inner face secure one side of the threaded sleeves to the upright face. 6 per side 45. If outer frame are not being fitted, place the end plates up against the threaded sleeves and fasten with the remaining M8 hardware. M8 - 24 Nm.

Fitting instructions# 3789248 Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd OUTEREFRAME INSTALLATION 46. If fitting the outer frames, loosely fasten the upright flange to the threaded sleeve as in above step. 47. Take the 2 M12 x 40mm bolts spring and flat washers and from inside the wing fasten the outer frame to the wing. Tighten to specified torque. 48. Check that the Bar is aligned to the vehicle and using a 10mm drill bit, drill through the 2 pinning holes through the outside face of the chassis. Ensure the nut plate is clear of the drill. Paint exposed areas with rust preventative paint. 49. Take the M10 x 40 SEMS bolts and fasten to the internal nut plate and tighten to specified torque. 2 per side. M10 - 44 Nm. 50. If no winch is fitted, secure license plate directly to bar using M6 dome head stainless steel screws, flange nuts and SS flat washers. 51. For vehicle with winch, fit license plate bracket shown. Also using M6 dome head stainless steel screws, flange nuts and SS flat washers. 52. If centre frame or outer frame kits were not installed, place plastic plugs supplied through the holes on top of bar. M6 - 9 Nm.

Fitting instructions# 3789248 Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd 53. For Non winch application, place the top cover on top of Centre section and fasten with 4 M6 button head screws, flat washers and flange nuts. 54. Using the 5 M10x30 SEMS bolts and flange nuts, fit the lower deflector to the underside of the lower pan to the lower holes in the anti - intrusion bars. 55. Scribe a parallel line from the bottom of the inner guard liner, just above the lower edge of the wing. 56. Cut with a suitable saw and de-bur the edges. 57. Tuck the outer edge in behind the wing flange.

Fitting instructions# 3789248 Copyright © 2005 by ARB Corporation Limited. All rights reserved, this document must not be reproduced without the express authority of ARB Corporation Ltd FITTED PRODUCT