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Land Rover Discovery I Deluxe and Winch Brush Bars Installation Instructions

Applies To:

Item: 9402ARBD8/9402ARBD9
Fits: Discovery I | '94 - '99

Fitting Kit Contains

  • 1 - Indicator Kit (contains left and right)
  • 2 - M6 x 16mm Bolts
  • 2 - M6 Flat Washers
  • 2 - M6 Flange Nut
  • 2 - Buffers
  • 4 - M8 Flange Nuts
  • 1 - Impact Absorber (left hand)
  • 1 - Impact Absorber (right hand)
  • 2 - Chassis Packer Inside
  • 2 - Chassis Packer Outside
  • 4 - 1/2" x 4-1/2" Bolt
  • 2 - 1/2" x5" Bolt
  • 2 - 40mm Heavy Duty Washers
  • 6 - 1/2" Spring Washers
  • 10 - 1/2" Flat Washers
  • 6 - 1/2" Nuts 1 - Cable Tie
  • 8 - M10 x 25mm Bolts
  • 8 - M10 Spring Washers
  • 6 - M10 Flat Washers
  • 8 - M10 x 1.25 Nuts

Additional Fitting Kit for the Winch Brush Bar

  • 2 - 1/4" Nuts
  • 2 - M6 Flat Washers
  • 2 - M6 Spring Washers
  • 4 - 1/4" Nuts
  • 2 - 1/4" x 1" Bolts
  • 4 - M6 Spring Washers
  • 1 - Control Box Bracket
  • 2 - M8 x 20mm Bolts
  • 2 - M8 Flat Washers
  • 2 - M8 Flange Nuts
  • 1 - Wiring Loom - Red
  • 1 - Wiring Loom - Black
  • 2 - M12 x 30mm Bolts
  • 2 - 1/2" Washer Springs
  • 4 - 1/2" Washer Flat
  • 2 - M12 x 1.25 Nuts
  • 1 - Winch Mount Cradle
  • 4 - 3/8" Flat Washers
  • 4 - 7/16" Washer Flat

IMPORTANT:

  • This brush bar and its mounting system is intended for an airbag equipped vehicle.
  • This brush bar MUST be fitted in accordance with these instructions. Failure to do so could affect occupant safety.
  • FOR WINCH BARS: When fitting the 10,000lb winch, ARB recommends that an Old Man Emu suspension kit be installed to the increased weight and subsequent reduction in ground clearance.

Tools Required

  • Basic tool kit
  • Level
  • Tape measure
  • Drill
  • 1/2" drill bit

Fitting Procedure

1. Disconnect the headlight washers at the T piece by cutting the tube; take care, as the T piece is fragile. NOTE: First temporarily block the tube to prevent loss of washer fluid.

2. Remove the bumper bar.

3. Remove the headlight washers and tubing from the bumper bar and fit to the bull bar. Make sure the tubing is fed through the holes in the brush bar uprights.

4. Fit the turn signal indicators supplied into the brush bar. NOTE: Refer to the instructions supplied with the turn signal indicator kit.

WINCH BARS: FITTING THE 8 OR 9,000lb WINCH

  • a.) Fit the control box to the control box bracket using the two 1/4" nuts, washers and spring washers. Bolt the control box bracket to the brush by using the M8 x 20mm bolts, flat washers and flange nuts supplied.

Control Box Bracket

  • b.) To place the winch clutch handle in a convenient location, the winch gearbox must be rotated 2 hole spacings, 72 degrees, in a clockwise direction when viewed from the gearbox end. Place the winch on its end and remove all gearbox bolts. Gently raise the gearbox just enough to rotate it. Do not completely remove the gearbox and avoid damaging the gasket. Refit all bolts and tighten.

Gearbox End Left Hand Side

Motor End Right Hand Side

Gearbox End Right Hand Side


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