Thule Brink 440400 Tow Bar Instruction Manual

1. Introduction

This manual provides detailed instructions for the safe and proper installation, operation, and maintenance of your Thule Brink 440400 Tow Bar. Please read this manual thoroughly before installation and use to ensure optimal performance and safety.

The Thule Brink 440400 Tow Bar is designed for specific vehicle models, including Audi A4 Avant (2004-2008) and Seat Exeo St (2009-). Always verify compatibility with your vehicle before installation.

2. Product Overview

Image: The Thule Brink 440400 Tow Bar shown installed on the rear of a blue Audi A4 Avant, demonstrating its discreet integration below the bumper.

The Thule Brink 440400 is a high-quality tow bar featuring a removable ball head, designed for vehicles requiring a towing capacity of up to 2000 kg. Its robust construction ensures reliable performance for various towing needs.

3. Setup and Installation

Proper installation is critical for the safe operation of the tow bar. Refer to the diagram below for component identification and torque specifications.

Image: An exploded view diagram illustrating the various components of the Thule Brink 440400 Tow Bar and their assembly points on a vehicle chassis. Key components are labeled with part numbers and required torque settings for bolts.

Installation Steps:

1. Preparation: Ensure the vehicle is on a level surface and properly supported. Disconnect the vehicle's battery if required by vehicle manufacturer instructions.
2. Component Identification: Identify all components as per the diagram: main tow bar frame (4404/4), removable ball head (9535300), and associated fasteners.
3. Mounting the Main Frame: Attach the main tow bar frame to the vehicle's chassis using the specified bolts (M10x100(10.9)) and washers (ø25x10,5x4). Torque these bolts to 45 Nm. Note the different fitting points for Audi models (2001-2004 vs. 2005->) and Seat Exeo (2009->).
4. Securing Side Brackets: Secure any auxiliary side brackets or supports using M6x50(10.9) bolts, torquing them to 15 Nm.
5. Attaching Ball Head Receiver: Install the ball head receiver mechanism (part of 4404/50) to the main frame.
6. Installing Removable Ball Head: Insert the removable ball head (9535300) into its receiver. Ensure it clicks securely into place. The M12x90(10.9) bolt for the ball head should be torqued to 110 Nm.
7. Electrical Connection (if applicable): If installing a wiring harness (not included with tow bar), follow the separate instructions for connecting vehicle electrics to the tow bar socket.
8. Final Check: Double-check all bolted connections for correct torque. Ensure no components interfere with vehicle operation or exhaust system.

4. Operating Instructions

Attaching a Trailer:

1. Ensure the tow bar ball head is clean and free of debris.
2. Carefully reverse your vehicle to align the tow bar ball with the trailer hitch.
3. Lower the trailer hitch onto the tow bar ball until it is fully seated and locked. Verify the connection is secure by attempting to lift the trailer hitch.
4. Connect the trailer's safety chain(s) to the designated attachment points on the tow bar or vehicle.
5. Connect the trailer's electrical plug to the vehicle's tow bar socket. Test all trailer lights (brake, turn signals, running lights) before driving.

Detaching a Trailer:

1. Park the vehicle and trailer on a level surface and engage the parking brake on both.
2. Disconnect the trailer's electrical plug and safety chain(s).
3. Raise the trailer hitch using its jockey wheel or support until it clears the tow bar ball.
4. Drive the vehicle slowly forward, away from the trailer.

5. Maintenance

• Regular Inspection: Periodically inspect the tow bar for any signs of damage, corrosion, or loose fasteners.
• Cleaning: Keep the tow bar ball and receiver mechanism clean and free of dirt and debris.
• Lubrication: Lightly grease the tow ball to reduce friction and wear during towing.
• Torque Check: Re-check the torque of all mounting bolts after the first 500 km (300 miles) of use and periodically thereafter.
• Storage (Removable Ball Head): When not in use, remove the ball head and store it in a clean, dry place to prevent corrosion and damage.

6. Troubleshooting

Common Issues:

• Difficulty attaching/detaching trailer: Ensure the tow ball and hitch are clean. Check for any obstructions or damage to the hitch mechanism.
• Excessive noise during towing: Check for loose connections or worn components. Ensure the tow ball is adequately greased.
• Trailer lights not working: Verify the electrical connection is secure. Check vehicle and trailer fuses. Inspect wiring for damage.
• Tow bar appears loose: Immediately stop towing. Inspect all mounting bolts and re-torque to specifications if necessary. Do not tow with a loose tow bar.

7. Specifications

8. Warranty and Support

Thule products are known for their quality and are backed by a limited warranty. For specific warranty terms and conditions, please refer to the warranty information provided with your purchase or visit the official Thule website.

For technical support, spare parts, or further assistance, please contact Thule customer service or your authorized Thule dealer. When contacting support, please have your product model number (440400) and purchase details ready.

You can visit the Thule Store for more information: Thule Official Store