Project 4runner Backcountry Part 4

129 1104 Project 4Runner Backcountry Part 4 Front Side View

When building a vehicle to enter the backcountry alone, it is crucial to plan for the worst and, in the immortal words of the Boy Scouts, "Be Prepared." In this case, that means having the ability to self-extract if we get stuck because nothing can ruin your day as quickly as immobility. We wanted to install a Warn winch on the front of our 4Runner, but were faced with limited options until ARB informed us that they had a brand new Bull Bar application that was compatible with the fifth-generation 4Runner.

129 1104 Project 4Runner Backcountry Part 4 Arb Bull Bar Kit

ARB provides everything you need for a successful Bull Bar installation. In addition to the ARB Bull Bar, we selected a 9,000-pound Warn XD9000 winch.

ARB provides everything you need for a successful Bull Bar installation. In addition to th

ARB's signature Bull Bars, recognizable on adventure rigs around the world, are designed to survive in the harsh environment of the Australian Outback. ARB engineered the Bull Bar for strength and reliability, and most Bull Bars are compatible with factory front airbag systems. Features of the Bull Bar include recessed fog lights and turn signal repeaters, tabs for antenna or flag mounting, reinforced winch mounting brackets that spread extreme winching loads across the chassis, and Hi-Lift lifting points. The ARB Bull Bar was the perfect product to provide us with a platform to mount our lighting and Warn winch, as well as protect the front end of the 4Runner.

129 1104 Project 4Runner Backcountry Part 4 Factory Bumper Beam

We began the ARB Bull Bar installation by removing the factory front bumper cover and the bumper beam.

We began the ARB Bull Bar installation by removing the factory front bumper cover and the

The Warn winch we used for this buildup is the classic and proven XD9000. This 9,000-pound-rated winch has a 38-foot per minute line speed rating using a reliable 4.6hp Series Wound motor and three-stage planetary gearset with a 156.1:1 gear ratio. The remote-mount control pack and compact body make it perfect for tight spaces, like our ARB Bull Bar, and it only weighs 78 pounds with 100 feet of wire rope.

Because the bumper we used on Project 4Runner Backcountry was one of the very first to arrive in the States, ARB had a representative fly from their U.S. headquarters in Renton, Washington, to our installation location at Off Road Evolution in Fullerton, California, to walk us through the intricacies of the install. We found the 4Runner Bull Bar to be a complicated install that took us two days at a deliberate pace. This is one install that is best done by a professional, or a few strong friends in the know. Because of the complexities, we will show you an overview of the major points to this installation.

Here you can see the Bull Bar side plates mounted to the frame horns.
These impact absorbers are what allow the Bull Bar to be compatible with the factory airbag system.
These impact absorbers are what allow the Bull Bar to be compatible with the factory airba
As soon as the bumper bracketry was in place on the 4Runner, we prepped the stock bumper cover and retaining clip by trimming it according to the template provided by ARB. A steady hand and painter's tape are the best ways of ensuring a straight line when you cut.
As soon as the bumper bracketry was in place on the 4Runner, we prepped the stock bumper c

We masked the fender off with painter's tape and painted what would now be an exposed section of fender with black paint to camouflage it to the bumper. We then reinstalled the modified bumper retaining clip.
We masked the fender off with painter's tape and painted what would now be an exposed sect
Next, the upper portion of the factory bumper cover was reinstalled, and pinch molding was used to clean up the cut line. The bumper cover is cut with a gap at the fender so that the Bull Bar has enough room to move without contacting and damaging the body. At this stage, the hardware is in place, but not tightened.
Next, the upper portion of the factory bumper cover was reinstalled, and pinch molding was
The Warn XD9000 winch could not be mated to the Bull Bar until we re-clocked it by carefully removing the end cap and rotating it 90 degrees. With the winch re-clocked, we mounted it to the ARB Bull Bar and added the roller fairlead.
The Warn XD9000 winch could not be mated to the Bull Bar until we re-clocked it by careful

Because of space constraints, ARB requires a winch with a remote control box. ARB provides the bracket for mounting the control box to the bumper.
Because of space constraints, ARB requires a winch with a remote control box. ARB provides
Next, we mounted the Warn control box to the Bull Bar and ran the wiring through the grommets to the winch.
Next, we mounted the Warn control box to the Bull Bar and ran the wiring through the gromm
With the winch and Bull Bar assembled, the bumper was then lifted in place on the 4Runner and secured with a few bolts. The trickiest part of the installation is making sure the bumper is spaced and leveled properly. This is where friends and a jack can come in handy. Once we were satisfied, we tightened up the mounting bolts.
With the winch and Bull Bar assembled, the bumper was then lifted in place on the 4Runner

After the bumper position was set and the bolts were tightened, we drilled four pinning bolt holes to ensure the bumper would never move.
After the bumper position was set and the bolts were tightened, we drilled four pinning bo
Diagonal bracing straps were then installed to fortify the winch mounts and spread loads on side pulls.
Diagonal bracing straps were then installed to fortify the winch mounts and spread loads o
A rock shield is used to connect the Bull Bar to the factory skidplate, and further protects the 4Runner underbody from damage.
A rock shield is used to connect the Bull Bar to the factory skidplate, and further protec

Next, we spliced into the factory wiring to get power for the new ARB driving lights and turn signals. The finished ARB driving lights and blinker are recessed in the Bull Bar for protection and work with the factory switchgear.
Next, we spliced into the factory wiring to get power for the new ARB driving lights and t
Lastly, we fitted the wing panels to the underside of the Bull Bar and trimmed the factory fender liner to match, giving our 4Runner a finished look.
Lastly, we fitted the wing panels to the underside of the Bull Bar and trimmed the factory
With the ARB Bull Bar and Warn winch installed, we aren't afraid to go a little bit deeper in the backcountry. It is great knowing that we have the capability to self-extract if the need arises and we love that the Bull Bar adds a functional, serious look to Project 4Runner Backcountry.
With the ARB Bull Bar and Warn winch installed, we aren't afraid to go a little bit deeper

SOURCES
Warn 12900 S.E. Capps Road Clackamas OR 97015 800-543-9276 www.warn.com	Off Road Evolution 1829 W Commonwealth Avenue Fullerton CA 92833 714-870-5515 www.offroadevolution.com
ARB 4x4 Products 720 SW 34th Street Renton WA 98057 800-761-8192 http://www.arbusa.com