The installation kit contains sufficient components for fitment*. Do not substitute any components. A high degree of technical competence is necessary to correctly install this product. We recommend this towbar be installed by an authorised outlet to ensure the installation complies with the requirements of AS 4177.1 Standard and ADR 62/00. These instructions must be read and clearly understood before commencing installation. *Note: Towbar package does not include any electrical components or mounting bracket for trailer socket. Installation time - Approximately 1.5 Hours WARNINGS The maximum towbar capacity may exceed the maximum allowable towing capacity of some vehicles. For model specific towing capacities and towball download specifications, please refer to the vehicle owners handbook or the manufacturer. Overloading can be dangerous and void your warranties. We recommend the use of a tow ball manufactured to comply with AS 4177.2. Strict compliance with fitting instructions is essential for this product to meet its rated capacity. Do not modify towbar in any way. Do not use this towbar on any other vehicle for which it is not designed. Modifications to the tow bar or its fixings or use on any other vehicle for which it is not designed may void the load rating and warranty. Where high tensile threaded fasteners are used, the towbar must be installed using the size and grade fasteners specified by Milford Industries. Do not remove the towbar information label from the towbar. To comply with ADR 42/00 clause 42.9 the towing lug should be removed when not in use. TOOLS REQUIRED Socket wrench Metric Hex Sockets Metric Spanners Torque wrench Touch up paint Side Cutters Power Drill Drill Bits 10mm, 14mm Imperial A/F Hex Sockets Imperial A/F Spanners Phillips head screwdriver Trim removal tools Metal panel cutting tools Bumper cutting tools Metal File Cotton Bud (rust preventative applicator) FASTENER TORQUES Fastener size Fastener grade/class Recommended torque 1/2 UNC 8 125Nm/92lbft M10 x 1.5 8.8 44Nm/32lbft Page No. 1 of 13
Parts List Important: Check contents of kit before commencing fitment and report any discrepancies or damage. Item Component Name Part No. Qty 1 Towbar ASM (See page 3) 191890 1 2 Towing Lug (See page 3) 191229 1 3 D Shackle (chain connection) 1949 2 3 4 5 6 4 Bolt 1/2 UNC x 1½ HT ZP 913149 2 5 Hex Nut 1/2 UNC ZP 913155 6 6 Washer Flat 1/2 ZP 932045 6 7 8 9 10 7 Washer Spring 1/2 ZP 913152 6 8 Bolt M10 x 50 HT ZP 913667 4 9 Bolt M10 x 35 HT ZP 912075 2 10 Hex Nut M10 ZP 922140 8 Washer Flat 10mm ZP 932005 14 12 Washer Spring 10mm ZP 932010 8 13 Bolt/Washer/Wire ASM (M10) ZP 190173 1x2 12 13 14 14 Rust Preventative Sealer (Sachet) 906300 1 15 Adhesive Label Identification/Tow bar information 905026 1 16 Angle Bracket (Short) (RH) 779490 1 17 Angle Bracket (Long) (LH) 779484 1 18 Bolt/Plate/Wire ASM (Short RH, Long LH) 190171 1x2 17 TOWBAR INFORMATION RUST PREVENTATIVE SEALER 15 18 16 Items 17 & 18 shown at reduced scale ADVICE TO FITTERS Note: To fit the towbar the following is essential: Always drill perpendicular to surface (Unless stated otherwise). A positive drill stop should always be used to prevent accidental damage to hidden panels, fuel lines etc. Ensure Safety Eye Protection and Gloves are worn as required when using cutting tools. When drilling/cutting metal panels be very careful of sharp edges, for risk of skin cuts etc. Care should be taken when applying Rust Preventative sealer to all holes drilled, to negate the possibility of skin and eye irritation. Check screws in relevant components by hand before installation. Should there be resistance re-tap threads and re-check. Before marking or drilling to install this towbar, check vehicle for LPG conversion & non standard fuel tanks. Locate tanks and all lines attached and take EXTREME CARE not to damage whilst installing this tow bar. Before drilling to install this towbar, check for concealed wiring looms. E.g. towbar, reversing camera, reversing sensor wiring etc.. Relocate before drilling to avoid damage. CARE SHOULD BE TAKEN NOT TO CROSS THREAD THE FASTENERS DURING INSTALLATION OF COMPONENTS TO THE VEHICLE. ALL FASTENERS SHOULD BE TIGHTENED TO THE RECOMMENDED TORQUES. Page No. 2 of 13
18 18 8 Vehicle chassis rail (cut away) 13 16 12 10 7 8 6 9 5 6 17 7 6 8 5 13 5 7 RHS 8 5 4 10 12 Back panel/member of vehicle 2 R Clip 3 1 Lug retaining pin 12 10 10 12 x2 Item 1 Towbar ASM 2 Towing Lug Component Name Item Component Name 9 Bolt M10 x 35 HT ZP 10 Hex Nut M10 ZP 3 D Shackle (chain connection) 4 Bolt 1/2 UNC x 1½ HT ZP 5 Hex Nut 1/2 UNC ZP 6 Washer Flat 1/2 ZP 7 Washer Spring 1/2 ZP 8 Bolt M10 x 50 HT ZP Washer Flat 10mm ZP 12 Washer Spring 10mm ZP 13 Bolt/Washer/Wire ASM (M10) ZP 16 Angle Bracket (Short) (RH) 17 Angle Bracket (Long) (LH) 18 Bolt/Plate/Wire ASM (Short RH, Long LH) Page No. 3 of 13
REMOVE REAR TAIL LIGHTS Remove screws indicated 1. Open tailgate and locate the 2 screws securing each of the tail lights in place. 2. Remove these screws and also the screw securing the bumper under the tail light. 3. Using a plastic trim removal tool or similar, carefully leaver the tail light rearwards to the vehicle, to release it from concealed retaining clips. 4. Disconnect wiring loom from tail light assembly and store tail light in a safe place. 5. Repeat steps 3 & 4 on other side. Page No. 4 of 13
REMOVE REAR BUMPER BAR 6. Remove the 5 clips securing the bottom rear edge of the bumper to the vehicle. Remove 5 clips Remove clip 7. Remove clip securing the bottom of the bumper to the vehicle just behind the rear wheel. 8. Repeat on other side. Remove screw Remove clips 9. Remove the screw & 2 clips securing the bumper inside the wheel arch. 10. For May 20 vehicles onward also remove the clip at the top front edge of the bumper. (Push wheel arch trim out of way to access). Repeat on other side. Note: Additional fasteners may be present if mud flaps have been installed. Additional clip for May 20 onward models Page No. 5 of 13
REMOVE REAR BUMPER BAR Continued 12. Carefully pull the sides of bumper outwards to release sides from concealed clips. Pre May 20 Remove screw Release clips Post May 20 13. For pre May 20 models remove screw securing bumper to vehicle located at the outside bottom of the tail light area. 14. For post May 20 models carefully release the double clips at the top edge of the bumper in the bottom of the tail light area. 15. Repeat on other side. 16. With all fasteners removed & clips released, carefully remove bumper from vehicle. Note: If the vehicle is fitted with reverse parking sensors, the wiring harness connection will need to be disconnected before the bumper can be removed. 17. Store bumper bar in a safe place until ready for marking/trimming for towbar opening. INSTALLATION OF THE TOW BAR TO THE VEHICLE CHASSIS 18. Familiarise yourself with the existing mounting points which will be used to secure towbar to vehicle chassis. Page No. 6 of 13
INSTALLATION OF THE TOW BAR TO THE VEHICLE CHASSIS Cont d Cross member flange 60mm 30mm 19. On the LHS of vehicle back panel locate the existing rectangular hole shown. 20. From this hole mark out the back panel as shown. 21. On the RHS of vehicle back panel locate the existing rectangular hole shown. 22. From this hole mark out the back panel as shown. 30mm LHS RHS 23. Using a jig saw or other suitable tool cut away the marked areas. 24. Using suitable file clean up rough edges. 25. Using suitable touch up paint, such as zinc rich primer, paint the raw edges of the cut area. Page No. 7 of 13
INSTALLATION OF THE TOW BAR TO THE VEHICLE CHASSIS Cont d 26. Remove the towbar tongue from the towbar assembly. 27. With the long towbar side bracket to the LHS of the vehicle, slide the side brackets into the new access holes cut out at step 21. 28. Locate the towbar end brackets over the vehicle rear cross member ends as shown. Items 8, x2, 12 & 10 29. On RHS place M10 bolt (Item 8) with flat washer (Item ) under head through rearmost side hole in rear cross member & towbar. 30. Secure bolt in place as shown using flat washer, spring washer & M10 hex nut. Leave loose at this stage. 31. Repeat on other side. Feed wire (Item 13) Items 8, x2, 12 & 10 Items 13,, 12 & 10 32. At the rearmost bottom holes in rear cross member ends, place M10 bolt (Item 8) with flat washer (Item ) under head through hole & towbar bracket. 33. Secure bolts in place as shown using flat washer, spring washer & M10 hex nut. Leave loose at this stage. 34. Cut Bolt/Washer/Wire ASM (Item 13) in half. 35. At the forward most side holes in rear cross member ends place M10 Bolt/ Washer/Wire ASM (Item 13) through hole and towbar bracket. 36. Secure bolts in place as shown using flat washer, spring washer & M10 hex nut. 37. Starting with bottom bolts semi tighten the 6x M10 bolts to position the towbar. Page No. 8 of 13
INSTALLATION OF THE TOW BAR TO THE VEHICLE CHASSIS Cont d Item 17 38. Attach long angle bracket (Item 17) to LH side towbar bracket as shown, using 1/2 UNC bolts (Item 4, flat washers, spring washers & 1/2 UNC hex nuts. Finger tighten only at this stage. Items 4, 6, 7 & 5 39. On RHS side of vehicle above exhaust muffler, flatten the back edge of heat shield in the vicinity of the towbar bracket as shown. Item 16 Items 9, x2 each bolt, 12 & 10 40. Attach short angle bracket (Item 16) to RH side towbar bracket as shown, using M10 x 35mm bolts (Item 9), flat washers, spring washers & M10 hex nuts. Finger tighten only at this stage. Extended drill bit may be required 41. With brackets pushed up hard against chassis & using the angle brackets as a drill guide, drill 4x 14mm holes through the chassis rail bottom surfaces only. 42. Apply rust preventative sealer (Item 14) to drilled holes. Page No. 9 of 13
INSTALLATION OF THE TOW BAR TO THE VEHICLE CHASSIS Cont d Refer page 3 for installation detail 43. Cut Bolt/Plate/Wire ASM (Item 18) in half. 44. On LHS pass the long Bolt/Plate/Wire ASM down the inside of the chassis rail, then locate the 2 bolts through the 2 holes drilled at step 39 & angle bracket. 45. On underside of vehicle secure angle bracket in place using flat washers, spring washers & 1/2 UNC hex nuts. Refer page 3 for installation detail 46. On RHS pass the short Bolt/Plate/Wire ASM down the inside of the chassis rail, then locate the 2 bolts through the 2 holes drilled at step 39 & angle bracket. 47. On underside of vehicle secure angle bracket in place using flat washers, spring washers & 1/2 UNC hex nuts. 48. Torque up all nuts and bolts as specified in table on page 1. 49. Cut off excess feed wire from items 13 & 18 to prevent rattles. Page No. 10 of 13
CUT REAR BUMPER TO FIT OVER TOWING LUG For vehicles from May 2004 to April 20 20mm 75mm 50. Using the mould form lines at the centre bottom edge of bumper bar as datum lines, carefully mark out the centre bottom edge of the rear bumper as shown. Note: Inside face of bumper shown. Bottom edge of bumper 51. Using suitable cutting tools remove the centre section marked out at step 50. Hint Drill approx. 10mm holes in the corners to cut into, giving a better finish. 52. Carefully clean up edge after cutting. For vehicles from May 20 to Onward 30mm 70mm (5mm) 53. Using the mould form lines at the centre bottom edge of bumper bar as datum lines, carefully mark out the centre bottom edge of the rear bumper as shown. Note: Inside face of bumper shown. Do not use trim plug hole to find bumper centre line. 120mm 54. Using suitable cutting tools remove the centre section marked out at step 50. Hint Drill approx. 10mm holes in the corners to cut into, giving a better finish. 55. Carefully clean up edge after cutting. Page No. of 13
RE-ASSEMBLE ALL PARTS TO VEHICLE 56. Complete any necessary wiring required for this vehicle. (Not included with this package) 57. Carefully slide the towbar cut out in the bumper bar over the towbar hitch receiver, then reinstall the rear bumper to the vehicle in reverse order to the removal process. Note: Remember to reconnect the parking sensor wiring if applicable. 58. Re-assemble all other items to the vehicle in reverse order to their removal. ASSEMBLE TOWING LUG TO TOWBAR 59. Fit Milford-Auto hitch receiver cover to towbar if purchased by customer. (Not included with this package) 60. Install the towing lug (Item 2) to the towbar and secure in place using lug retaining pin and R clip supplied. 61. Install D shackles (Item 3) to towbar. Page No. 12 of 13
APPLICATION OF ADHESIVE LOAD RATING LABEL Item 15 62. Affix towbar information label (Item 15) in a conspicuous location on the inner panel of the drivers door opening. Note: Ensure panel is free of dirt and grease before applying. Towbar installation complete. Page No. 13 of 13